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FREQUENTLY ASKED QUESTIONS
If your question is not answered here, please check our BUILD IT FAQ as well. Still have questions? Please email us!
What is the am-cor™ system?
The am-cor™ system is a unified steel and cement building system, made entirely of inorganic materials. It is composed of a thin, highly reinforced structural skin; this skin consists of a special cement mix of portland cement, sand, and amcorite™ structural gel additive combined with an enveloping carbon steel mesh. This cement and mesh skin bonds to the steel frame, creating a unified monocoque structure. More information can be found in our SYSTEM OVERVIEW.
Why use am-cor™?
There are many reasons to use the am-cor™ system, not the least of which are its disaster resistance, use of environmentally friendly and green materials, and speed of completion. Please see our SYSTEM OVERVIEW for a complete list!
What materials are used in the am-cor™ system?
am-cor™ frames are composed of light gauge cold rolled galvanized steel sections. am-cor™ cement skins are composed of portland cement, sand, and amcorite™ cement additive. The cement skin is reinforced using galvanized carbon steel expanded metal sheathing. All these materials are inert, fire resistant, vermin resistant, and environmentally friendly. More information can be found here.
Do you have a presence or builder in my area?
Possibly, however am-cor™ PAKS can be shipped to any location and can be constructed by local builders. am-cor inc. coordinates with the builder of your choice. Included in every am-cor™ kit are illustrated field manuals and on-site builder/crew training.
How much will my building cost?
Please see our CURRENT COST page.
How long will it take to build?
am-cor™ shells can be enclosed extremely quickly and without heavy equipment (cranes, heavy trucks, etc.). For example, a single story PANEL PAK residential structure of under 2000 sq. ft. can be assembled on prepared foundation in approximately 4 working days by a 7 member framing crew. Application of the amcorite™ structural skin takes approximately 4 more days. Roofing takes one day. Total elapsed time to dry-in the am-cor™ shell: 9 working days (allowing for weather and climate).
Why use the am-cor™ system as opposed to wood framing?
We were just waiting for you to ask. The am-cor™ system is superior in many ways to wood framing: it is fire resistant, rot, vermin and termite resistant; am-cor™ shells are hurricane, earthquake, and flood resistant. am-cor™ materials are inert, non-toxic, and environmentally friendly. More information can be found in our SYSTEM section.
Why use the am-cor™ system as opposed to metal buildings?
Metal building systems are sheathed in metal or exterior drywall, which are limited in durability and appearance. The am-cor™ ferrocement skin bonds to the light gauge steel frame to create a unified structure, which is durable and attractive. Exteriors of metal buildings are corrugated steel, which have limited use because of appearance. am-cor™ buildings have beautiful cement exteriors which can be textured, tinted, and ornamented to the designer's specification.
Additionally, a factory-controlled setting allows for high quality panel fabrication, reducing on-site framing time. am-cor™ panels are embedded into concrete footings and concrete floor slabs to create structures resistant to hurricanes, tornadoes, floods and earthquakes. The amcorite™ reinforced cement skin adheres to the steel frame to make the building shell a single extremely strong monocoque structure. Cement paint or water resistant white cement finish coats are applied to exposed surfaces and can be tinted, textured, and ornamented for beautiful and durable exteriors.
How does the am-cor™ system compare with an ICF structure?
The am-cor™ unified steel and cement system forms monocoque structures which provide extreme strength and durability. An ICF structure provides no structural link between foundation and wall or wall and roof. am-cor™ structural members are prepunched for easy installation of pipes and wires. An ICF structure has no easy way to run concealed services. amcorite provides an extremely durable and attractive exterior facing. An ICF structure has no provision for integrating a structural exterior facing.
How does the am-cor™ system differ from standard steel and stucco structures?
Standard steel frames are sheathed with exterior gypsum drywall or with corrugated metal. These systems rely upon screwed fasteners, which may loosen with successive windstorms. Conversely, am-cor™ steel frames are coated with a Portland cement and sand mixture using amcorite™ cement additive, and reinforced with galvanized carbon steel mesh. This mixture is applied as a continuous ferrocement skin on site to completely “glue” the frame together. Although fasteners are used to hold the mesh to the steel frame during construction, once the cement coat sets the frame is unified with the building skin, forming a strong and durable structure.
How does amcorite™ coating differ from other stucco materials?
am-cor™ exterior coatings are not plastic base finishes, although the appearance is similar. amcorite™ is a highly reinforced proprietary composite of cement, fibers, and additives to improve workability during application, as well as to reduce shrinkage during curing. There are no plastics, fillers, or organic additives to create problems, such as separation of the stucco surface from the frame, as with EIFS products. amcorite™ coating is applied directly to steel frame members, not to an intermediate foam board sheathing, as with EIFS. am-cor™ exteriors are not affected by delamination, cracking, moisture penetration, or other problems associated with EIFS surfacing systems, synthetic stucco, or organic based exterior finishes. Plastic stuccos will out-gas and melt with fire. am-cor™ unified steel & cement structures have 1 and 2 hour fire ratings, no out-gassing with fire, and no contribution to flame. Because they are made with Portland cement, am-cor™ exteriors are impervious to insects, birds, vermin, and termites. Because of the cement base of amcorite™, it is extremely long lasting.
Is am-cor™ construction cost-effective?
With rising cost of wood products and indeterminate quality of “stick” material, steel will become the first choice for framing in the coming years. The am-cor™ system provides pre-engineered structural building shell kits which can be site assembled, and coated with extremely durable amcorite™ structural cement skins quickly and easily. am-cor PANEL PAKS are less expensive and faster to ship and erect than standard masonry and concrete construction. However, in certain regions of the United States, the cement coat application is expensive due to application labor cost; in these areas, the am-cor™ system is slightly more expensive than stick-built vinyl sided structures. But where a stucco appearance is preferred, labor cost and construction time are less using am-cor™ than conventional “stick” construction with EIFS plastic base stucco finish.
Where are the cost savings in using of the am-cor™ system?
The am-cor™ system requires substantially less material than conventional construction to enclose space. This results in material, transportation, and labor savings. Design engineering and prefabrication of the system reduces onsite assembly time of the building shell, thereby reducing labor costs, cost of construction loans, and site overheads. Long-term maintenance and disaster repair costs are much lower with am-cor™ structures.
Are am-cor™ buildings environmentally friendly?
am-cor™ structures are inherently environmentally friendly, and we make an effort to be even friendlier. Heat energy is required to create structural materials such as brick, concrete, steel, and cement based unit masonry. Plastics are hydrocarbon based, made from fossil fuels (oil). Wooden construction stresses timber resources. Replacement of wooden buildings destroyed by natural disasters further depletes timberlands. Durable am-cor™ structures use a fraction of the steel and cement normally required, reducing pollution and stress on the environment. Check out our GREEN section to see the environmental benefits of the am-cor™ system, and our OPTIONS page for solar and energy saving additions to your am-cor™ structure.
Why is there no mildew or vermin with the am-cor™ system?
am-cor™ building shells provide the basis for healthy interiors. The am-cor™ system is vermin resistant because mice and rats cannot dig through steel studs or track in order to enter and move between frame cavities. There is no nesting material or food to support insects, mold, mildew, fungus, or vermin inside the am-cor™ frame. There are no organic elements in the system such as sugars or proteins to contribute to the growth of mildew, fungus, or rot, and as such the am-cor™ system is more durable than wood framing. More information can be found here.
Will am-cor™ system buildings rust?
No, there is no exposed steel in the system to rust. A zinc coating on the steel framing, called galvanization, protects the frame from corrosion for the life of the structure. Even the carbon steel mesh reinforcing for the amcorite™ skin is galvanized. Fasteners provided with the system are chromium and zinc plated for rust resistance. Security shutters, structural roof tile, roof trim, and exterior steel raised panel doors are all factory baked on enamel, protecting them from erosion.
Is an am-cor™ system building safe in a lightning storm?
The am-cor™ steel frame structure is imbedded into concrete footings, and so is totally grounded, providing multiple paths for lightning directly to ground. This reduces voltage concentration and likelihood of fire. Lightning rods are not required for am-cor™ shells.
What type of exterior finishes can be used with the am-cor™ system?
Exterior masonry facing materials are compatible with am-cor™ construction. am-cor™ frame panels can be supplied with brick clips at 2’-0” o/c. While the unified cement coating is preferred for durability and appearance, cement board siding may be applied using self-tapping bugle head screws supplied with your am-cor™ PAK. Standard exterior elements such as quoins, keystones and other ornamental trim may be applied or formed by layering successive amcorite™ coats onto the facade.
What is the best way to finish am-cor™ interiors?
Anything suitable for wood framing, such as wood paneling or gypsum drywall in a variety of finishes. Cement finishes similar to the amcorite™ exterior are also popular.
Can standard materials and methods be used to complete am-cor™ interiors?
Since wall and floor framing components are pre-punched at the factory, electrical wires and plumbing may be installed without much drilling. Plastic grommets are used to keep service runs from touching the steel framework. Commercial drywall contractors use power screw guns to apply gypsum drywall interiors. Square-drive trim screws are used to attach finishes, baseboard, and moldings. Self-tapping screws are used to mount wall cabinets, accessories, pictures, etc. to steel studs and blocking.
How are insulation and services installed?
Although Icynene, or recycled wood fiber treated with Borax, spray insulations are recommended to completely seal the shell, fiberglass battens may also be used to insulate am-cor™ steel frames. First install pipes and wires through the factory-punched holes in studs, joists, and rafters using plastic grommets to keep service runs from touching the steel frame. Then spray insulation, or pack battens around the services and into the C profiles for complete thermal break. Rigid water resistant foam board is fastened to the subgrade face of wall studs and secured using the carbon steel mesh from top of footer to top of slab in order to isolate the floor and foundation wall from exterior temperature variation.
What if I want to install radiant floor heating in my building?
The am-cor™ system was developed with this type of heating in mind. It is our opinion that solar based radiant is the most efficient way to heat a structure, saving both cost of purchase and operation of HVAC equipment. Radiant floors and ceilings may be heated by a gas-fired boiler, or by solar panels with gas backup. So for a little more than the cost of a large water heater, gentle heat may be distributed throughout interiors via the structure itself. Both steel and cement are conductive, and cement has great thermal inertia, making your am-cor™ building shell an ideal medium for integral heat distribution and energy conservation.
Can I hang pictures as in a normal stick-built house?
Yes, pictures and other decoration can be mounted using self-tapping screws at stud locations, or by standard drywall anchors between studs, just as in wood-framed buildings.
What would be a normal span for an am-cor™ roof?
am-cor™ trusses span 40' to 50'. am-cor™ rafters span 20' to 25'.
Can the am-cor™ system be used for basement walls along with the above grade walls?
am-cor inc. provides pre-engineered basement wall panels with are embedded in the footer and integrated structurally with the superstructure. This system is approved in all US states. Unlike sold wall basement walls, am-cor™ cavity walls provide ready space for insulation and concealed services, should the owner wish to finish basement areas.
GENERAL
What is the am-cor™ system?
The am-cor™ system is a unified steel and cement building system, made entirely of inorganic materials. It is composed of a thin, highly reinforced structural skin; this skin consists of a special cement mix of portland cement, sand, and amcorite™ structural gel additive combined with an enveloping carbon steel mesh. This cement and mesh skin bonds to the steel frame, creating a unified monocoque structure. More information can be found in our SYSTEM OVERVIEW.
Why use am-cor™?
There are many reasons to use the am-cor™ system, not the least of which are its disaster resistance, use of environmentally friendly and green materials, and speed of completion. Please see our SYSTEM OVERVIEW for a complete list!
What materials are used in the am-cor™ system?
am-cor™ frames are composed of light gauge cold rolled galvanized steel sections. am-cor™ cement skins are composed of portland cement, sand, and amcorite™ cement additive. The cement skin is reinforced using galvanized carbon steel expanded metal sheathing. All these materials are inert, fire resistant, vermin resistant, and environmentally friendly. More information can be found here.
Do you have a presence or builder in my area?
Possibly, however am-cor™ PAKS can be shipped to any location and can be constructed by local builders. am-cor inc. coordinates with the builder of your choice. Included in every am-cor™ kit are illustrated field manuals and on-site builder/crew training.
How much will my building cost?
Please see our CURRENT COST page.
How long will it take to build?
am-cor™ shells can be enclosed extremely quickly and without heavy equipment (cranes, heavy trucks, etc.). For example, a single story PANEL PAK residential structure of under 2000 sq. ft. can be assembled on prepared foundation in approximately 4 working days by a 7 member framing crew. Application of the amcorite™ structural skin takes approximately 4 more days. Roofing takes one day. Total elapsed time to dry-in the am-cor™ shell: 9 working days (allowing for weather and climate).
COMPARISON
Why use the am-cor™ system as opposed to wood framing?
We were just waiting for you to ask. The am-cor™ system is superior in many ways to wood framing: it is fire resistant, rot, vermin and termite resistant; am-cor™ shells are hurricane, earthquake, and flood resistant. am-cor™ materials are inert, non-toxic, and environmentally friendly. More information can be found in our SYSTEM section.
Why use the am-cor™ system as opposed to metal buildings?
Metal building systems are sheathed in metal or exterior drywall, which are limited in durability and appearance. The am-cor™ ferrocement skin bonds to the light gauge steel frame to create a unified structure, which is durable and attractive. Exteriors of metal buildings are corrugated steel, which have limited use because of appearance. am-cor™ buildings have beautiful cement exteriors which can be textured, tinted, and ornamented to the designer's specification.
Additionally, a factory-controlled setting allows for high quality panel fabrication, reducing on-site framing time. am-cor™ panels are embedded into concrete footings and concrete floor slabs to create structures resistant to hurricanes, tornadoes, floods and earthquakes. The amcorite™ reinforced cement skin adheres to the steel frame to make the building shell a single extremely strong monocoque structure. Cement paint or water resistant white cement finish coats are applied to exposed surfaces and can be tinted, textured, and ornamented for beautiful and durable exteriors.
How does the am-cor™ system compare with an ICF structure?
The am-cor™ unified steel and cement system forms monocoque structures which provide extreme strength and durability. An ICF structure provides no structural link between foundation and wall or wall and roof. am-cor™ structural members are prepunched for easy installation of pipes and wires. An ICF structure has no easy way to run concealed services. amcorite provides an extremely durable and attractive exterior facing. An ICF structure has no provision for integrating a structural exterior facing.
How does the am-cor™ system differ from standard steel and stucco structures?
Standard steel frames are sheathed with exterior gypsum drywall or with corrugated metal. These systems rely upon screwed fasteners, which may loosen with successive windstorms. Conversely, am-cor™ steel frames are coated with a Portland cement and sand mixture using amcorite™ cement additive, and reinforced with galvanized carbon steel mesh. This mixture is applied as a continuous ferrocement skin on site to completely “glue” the frame together. Although fasteners are used to hold the mesh to the steel frame during construction, once the cement coat sets the frame is unified with the building skin, forming a strong and durable structure.
How does amcorite™ coating differ from other stucco materials?
am-cor™ exterior coatings are not plastic base finishes, although the appearance is similar. amcorite™ is a highly reinforced proprietary composite of cement, fibers, and additives to improve workability during application, as well as to reduce shrinkage during curing. There are no plastics, fillers, or organic additives to create problems, such as separation of the stucco surface from the frame, as with EIFS products. amcorite™ coating is applied directly to steel frame members, not to an intermediate foam board sheathing, as with EIFS. am-cor™ exteriors are not affected by delamination, cracking, moisture penetration, or other problems associated with EIFS surfacing systems, synthetic stucco, or organic based exterior finishes. Plastic stuccos will out-gas and melt with fire. am-cor™ unified steel & cement structures have 1 and 2 hour fire ratings, no out-gassing with fire, and no contribution to flame. Because they are made with Portland cement, am-cor™ exteriors are impervious to insects, birds, vermin, and termites. Because of the cement base of amcorite™, it is extremely long lasting.
Is am-cor™ construction cost-effective?
With rising cost of wood products and indeterminate quality of “stick” material, steel will become the first choice for framing in the coming years. The am-cor™ system provides pre-engineered structural building shell kits which can be site assembled, and coated with extremely durable amcorite™ structural cement skins quickly and easily. am-cor PANEL PAKS are less expensive and faster to ship and erect than standard masonry and concrete construction. However, in certain regions of the United States, the cement coat application is expensive due to application labor cost; in these areas, the am-cor™ system is slightly more expensive than stick-built vinyl sided structures. But where a stucco appearance is preferred, labor cost and construction time are less using am-cor™ than conventional “stick” construction with EIFS plastic base stucco finish.
Where are the cost savings in using of the am-cor™ system?
The am-cor™ system requires substantially less material than conventional construction to enclose space. This results in material, transportation, and labor savings. Design engineering and prefabrication of the system reduces onsite assembly time of the building shell, thereby reducing labor costs, cost of construction loans, and site overheads. Long-term maintenance and disaster repair costs are much lower with am-cor™ structures.
SAFETY AND DURABILITY
Are am-cor™ buildings environmentally friendly?
am-cor™ structures are inherently environmentally friendly, and we make an effort to be even friendlier. Heat energy is required to create structural materials such as brick, concrete, steel, and cement based unit masonry. Plastics are hydrocarbon based, made from fossil fuels (oil). Wooden construction stresses timber resources. Replacement of wooden buildings destroyed by natural disasters further depletes timberlands. Durable am-cor™ structures use a fraction of the steel and cement normally required, reducing pollution and stress on the environment. Check out our GREEN section to see the environmental benefits of the am-cor™ system, and our OPTIONS page for solar and energy saving additions to your am-cor™ structure.
Why is there no mildew or vermin with the am-cor™ system?
am-cor™ building shells provide the basis for healthy interiors. The am-cor™ system is vermin resistant because mice and rats cannot dig through steel studs or track in order to enter and move between frame cavities. There is no nesting material or food to support insects, mold, mildew, fungus, or vermin inside the am-cor™ frame. There are no organic elements in the system such as sugars or proteins to contribute to the growth of mildew, fungus, or rot, and as such the am-cor™ system is more durable than wood framing. More information can be found here.
Will am-cor™ system buildings rust?
No, there is no exposed steel in the system to rust. A zinc coating on the steel framing, called galvanization, protects the frame from corrosion for the life of the structure. Even the carbon steel mesh reinforcing for the amcorite™ skin is galvanized. Fasteners provided with the system are chromium and zinc plated for rust resistance. Security shutters, structural roof tile, roof trim, and exterior steel raised panel doors are all factory baked on enamel, protecting them from erosion.
Is an am-cor™ system building safe in a lightning storm?
The am-cor™ steel frame structure is imbedded into concrete footings, and so is totally grounded, providing multiple paths for lightning directly to ground. This reduces voltage concentration and likelihood of fire. Lightning rods are not required for am-cor™ shells.
FINISHING
What type of exterior finishes can be used with the am-cor™ system?
Exterior masonry facing materials are compatible with am-cor™ construction. am-cor™ frame panels can be supplied with brick clips at 2’-0” o/c. While the unified cement coating is preferred for durability and appearance, cement board siding may be applied using self-tapping bugle head screws supplied with your am-cor™ PAK. Standard exterior elements such as quoins, keystones and other ornamental trim may be applied or formed by layering successive amcorite™ coats onto the facade.
What is the best way to finish am-cor™ interiors?
Anything suitable for wood framing, such as wood paneling or gypsum drywall in a variety of finishes. Cement finishes similar to the amcorite™ exterior are also popular.
Can standard materials and methods be used to complete am-cor™ interiors?
Since wall and floor framing components are pre-punched at the factory, electrical wires and plumbing may be installed without much drilling. Plastic grommets are used to keep service runs from touching the steel framework. Commercial drywall contractors use power screw guns to apply gypsum drywall interiors. Square-drive trim screws are used to attach finishes, baseboard, and moldings. Self-tapping screws are used to mount wall cabinets, accessories, pictures, etc. to steel studs and blocking.
How are insulation and services installed?
Although Icynene, or recycled wood fiber treated with Borax, spray insulations are recommended to completely seal the shell, fiberglass battens may also be used to insulate am-cor™ steel frames. First install pipes and wires through the factory-punched holes in studs, joists, and rafters using plastic grommets to keep service runs from touching the steel frame. Then spray insulation, or pack battens around the services and into the C profiles for complete thermal break. Rigid water resistant foam board is fastened to the subgrade face of wall studs and secured using the carbon steel mesh from top of footer to top of slab in order to isolate the floor and foundation wall from exterior temperature variation.
What if I want to install radiant floor heating in my building?
The am-cor™ system was developed with this type of heating in mind. It is our opinion that solar based radiant is the most efficient way to heat a structure, saving both cost of purchase and operation of HVAC equipment. Radiant floors and ceilings may be heated by a gas-fired boiler, or by solar panels with gas backup. So for a little more than the cost of a large water heater, gentle heat may be distributed throughout interiors via the structure itself. Both steel and cement are conductive, and cement has great thermal inertia, making your am-cor™ building shell an ideal medium for integral heat distribution and energy conservation.
Can I hang pictures as in a normal stick-built house?
Yes, pictures and other decoration can be mounted using self-tapping screws at stud locations, or by standard drywall anchors between studs, just as in wood-framed buildings.
TECHNICAL
What would be a normal span for an am-cor™ roof?
am-cor™ trusses span 40' to 50'. am-cor™ rafters span 20' to 25'.
Can the am-cor™ system be used for basement walls along with the above grade walls?
am-cor inc. provides pre-engineered basement wall panels with are embedded in the footer and integrated structurally with the superstructure. This system is approved in all US states. Unlike sold wall basement walls, am-cor™ cavity walls provide ready space for insulation and concealed services, should the owner wish to finish basement areas.
Modified 2006-05-15