PO BOX 111
Elkwood, VA 22718 USA
+1 540 349 5895

Stick-Built Comparison

Overview

am‑cor FerroStress wall assembly

am‑cor FerroStress wall assembly

The am‑cor System is a structural building system:
The patented am-cor Ferrocement Construction System compares favorably with Stick-Built Wood Framing construction. There are a number of benefits to using the am-cor System, including strength, and labor and material savings. In its standard configuration the am-cor System is generally:
  • True Sustainability: am‑cor Ferrocement building shells require minimal upkeep and maintenance and have an exceptionally long lifespan; meaning you never have to worry about fire, mold, mildew, termites, insects, vermin, or natural disasters
  • Lower Carbon Footprint: prefabricated & preengineered = a low carbon footprint (less shipping, less transportation, less waste, etc.)
  • 8x The Strength: The am‑cor System's patented FerroStress™ technology & high strength-to-weight ration creates a continuous, unibody Ferrocement stress skin using amcorite™ structural gel, providing 6 times the unit strength of standard wood members.
  • 2x Faster: The am‑cor System is panelized and pre-engineered; walls are erected and set in minutes.
  • Unibody Integration: The am‑cor System integrates all structural elements (walls, beams, columns, headers, floors, etc.) into high strength panels, which are joined together into a single unified Ferrocement composite
  • Services & Insulation: am‑cor's hollow wall system allows for quick & easy placement of services and insulation, and does not require drilling or chipping for conduit, etc.


Shell Construction Comparison

This is a step-by-step comparison of the am‑cor Ferrocement Construction System and standard Stick-Built Wood Framing construction.

As a reference, we use The Tropic Cayman 3BR: a 1 story, 1650 sq.ft. plan, with the goal of creating a Dried-In Building Shell, complying with the IBC (International Building Code).
Dried-In Building Shell Comparison
The Tropic Cayman 3BR
am‑cor System
Ferrocement Prefab Kit
Standard Construction
Wood Stick-Built Framing
am‑cor Kit SpecificationsPlatform Framing Specifications
  • purchase standard plan or hire architect & engineer to provide permit and working drawing set
  • foundation/stem walls of reinforced concrete/masonry
  • stick-built wood framing
  • intermediate floors of wood joists, plywood decking
  • shingled wood truss roof
  • sheathing & house wrap/black paper
  • wood or vinyl siding
  1. Foundation: Reinforced Concrete Strip Footing
    am‑cor SystemWood Construction
    Labor Savings: approximately 25%
    Material Savings: approximately 15%
    step task material
    1line outstring & batter boards
    2prepare & set reinforcingreinforcing bars & tie wire
    3cast footingspoured concrete (smooth & level)
    step task material
    1line outstring & batter boards
    2prepare & set reinforcingreinforcing bars & tie wire
    3prepare & bend hooked barsreinforcing bars
    4set hooked barstie wire
    5cast footingspoured concrete (smooth & level)
  2. Foundation: Stem/Basement Wall of (a) Reinforced Concrete, or (b) Masonry
    am‑cor SystemWood Construction
    Labor Savings: approximately 50%
    Material Savings: approximately 40%
    Notes: all openings preframed in the factory; all design & engineering preapproved; walls ready for services, insulation & interior surfaces; no scraps, waste, or mess

    steptaskmaterial
    1consult drawingsam‑cor Field Manual
    2set labeled am‑cor wall panelsfasteners included
    3apply amcorite structural ferrocement coatamcorite, Portland cement, sand, water
    4waterproof subgrade wallstandard foundation waterproofing
    steptaskmaterial
    1consult drawingsarchitectural or standard plan
    2measure & make openingstreated jambs, heads & sills
    3custom build formworktreated wood & plywood
    4set concrete formsforms, spacers, ties
    5prepare & set reinforcingreinforcing bars & tie wire
    6set sill plate anchorsembedded threaded rods/bolts
    7acast concretepoured concrete
    7blay masonryunit masonry
    8aremove formworklabor & time
    8bgrout masonrymasonry grout mix
    9arub concretecement & water
    9bparge blockworkcement & sand parging mix
    10waterproof subgrade wallstandard foundation waterproofing
    11interior partitions & furringtreated wood
  3. Floor: Slab on Grade/Basement Floor Slab
    am‑cor SystemWood Construction
    Labor Savings: approximately 20%
    Material Savings: approximately 10%
    Notes: no formwork construction & material; no waste
    steptaskmaterial
    1prepare slab basegravel, slab insulation
    2groundworks (plumbing)plumbing supplies
    3prepare & set reinforcingreinforcing bars & tie wire
    4place vapor sealplastic sheeting
    5cast floor slabpoured concrete
    steptaskmaterial
    1prepare slab basegravel, slab insulation
    2groundworks (plumbing)plumbing supplies
    3prepare & place formworkwooden forms, spacers, ties
    4prepare & set reinforcingreinforcing bars & tie wire
    5place vapor sealplastic sheeting
    6cast floor slabpoured concrete
    7remove & discard formwork
  4. Floor: Upper Level Decking
    am‑cor SystemWood Construction
    Labor Savings: approximately 20%
    Material Savings: approximately 15%
    Notes: all openings preframed in the factory; all design & engineering preapproved; floor ready for services, insulation & interior surfaces; no scraps, waste, nor mess
    steptaskmaterial
    1consult drawingsam‑cor Field Manual
    2set labeled am‑cor floor panelsam‑cor Kit includes fasteners
    3apply amcorite ferrocement subflooramcorite, sand & cement
    steptaskmaterial
    1consult drawingsarchitectural or standard plan
    2consult codespans and stair opening header
    3measure & cut floor joistswooden framing material
    4measure & cut header & bandwooden framing material
    5frame & fasten materialwood, fasteners
    6measure & cut plywoodapproved, rated plywood
    7apply & fasten floor deckfasteners
  5. Walls: Ground Floor Exterior Walls
    am‑cor SystemWood Construction
    Labor Savings: approximately 80%
    Material Savings: approximately 75%
    Notes: wall panels already placed in previous step: "Foundation: Stem Wall" or "Floor: Slab on Grade"; all openings preframed in the factory; all design & engineering already preapproved; floor ready for services, insulation & interior surfaces; no scraps, waste, nor mess; exterior surfaces ready for finishing
    steptaskmaterial
    1flash openingsflashing material
    2insert windows & doorsexterior doors & windows
    3apply amcorite structural ferrocement coatamcorite, sand & cement
    4seal around openingsmodulus & caulking
    steptaskmaterial
    1consult drawingsarchitectural or standard plan
    2consult codeopening headers
    3measure & cut headers & sills for framingwooden material
    4measure & cut studs, corner bracingwooden material
    5frame & fasten materialfasteners
    6measure & cut sheathingOSB or plywood
    7apply & fasten sheathingfasteners
    8flash openingsflashing material
    9insert windows & doorsexterior openings
    10flash exterior of openingsflashing & weatherproofing
    11seal around openingsmodulus & caulking
    12apply weather sealhouse wrap or black paper
  6. Walls: Upper Floors Exterior Walls
    am‑cor SystemWood Construction
    Labor Savings: approximately 45%
    Material Savings: approximately 35%
    Notes: all openings preframed in the factory; all design & engineering already preapproved; floor ready for services, insulation & interior surfaces; no scraps, waste, nor mess; exterior surfaces ready for finishing
    steptaskmaterial
    1consult drawingsam‑cor Field Manual
    2set labeled am‑cor wall panelsam‑cor Kit includes fasteners
    3flash openingsflashing & weatherproofing
    4insert windows & doorsexterior doors & windows
    5apply amcorite structural ferrocement coatamcorite, sand & cement
    6seal around openingsmodulus & caulking
    steptaskmaterial
    1consult drawingsarchitectural or standard plan
    2consult codeopening headers
    3measure & cut headers & sills for framingwooden material
    4measure & cut studs, corner bracingwooden material
    5frame & fasten materialfasteners
    6measure & cut sheathingOSB or plywood
    7apply & fasten sheathingfasteners
    8flash openingsflashing material
    9insert windows & doorsexterior doors & windows
    10flash exterior of openingsflashing & weatherproofing
    11seal around openingsmodulus & caulking
    12apply weather sealhouse wrap or black paper
  7. Walls: Partitions
    am‑cor SystemWood Construction
    Labor Savings: approximately 50%
    Material Savings: approximately 25%
    Notes: all openings preframed in the factory; all design & engineering already preapproved; walls ready for services, insulation & interior surfaces; no scraps, waste, nor mess
    steptaskmaterial
    1consult drawingsam‑cor Field Manual
    2set labeled am‑cor partition panelsam‑cor Kit includes fasteners
    steptaskmaterial
    1consult drawingsarchitectural or standard plan
    2measure & cut door headers for framingwood framing material
    3measure & cut studs & plates for framingwooden material
    4measure & cut studs, corner bracingwooden material
    5frame & fasten materialfasteners
  8. Roof: Framing & Decking
    am‑cor SystemWood Construction
    Labor Savings: approximately 10%
    Material Savings: approximately 10%
    Notes: all openings preframed in the factory; all design & engineering already preapproved; roof ready for services, insulation & interior surfaces; no scraps, waste, nor mess
    steptaskmaterial
    1consult drawingsam‑cor Field Manual
    2set labeled am‑cor roof panelsam‑cor Kit includes fasteners
    3apply roof decking: rated plywood or amcorite ferrocement
    plywood or amcorite, sand, and cement; am‑cor Kit includes fasteners
    4apply & fasten metal fascia, rake & soffitincluded in am‑cor Kit
    5cover with black paper or amcorite ferrocementasphalt paper or concrete sealer
    6apply roofingshingles or waterproofing, fasteners
    steptaskmaterial
    1consult drawingsarchitectural or standard plan
    2set wood trussesengineered wooden roof trusses
    3install truss anchorstruss anchors, fasteners
    4apply rated plywood deckingrated plywood, fasteners
    5apply & fasten fascia, rake & soffitwood fascia, fasteners
    6cover with black paperasphalt paper, fasteners
    7apply roofingshingles/waterproofing
  9. Services: Plumbing, Electrical, HVAC, AV, etc.
    am‑cor SystemWood Construction
    Labor Savings: approximately 30%
    Material Savings: approximately 5%
    steptaskmaterial
    1install grommets in pre- punched studsam‑cor Kit includes grommets
    steptaskmaterial
    1consult drawings/ codebooks: limited hole size & locationarchitectural or standard plan/ codebooks
    2drill/chip for service runsdrilling equipment
  10. Balconies & Porches: Covered & Uncovered
    am‑cor SystemWood Construction
    Labor Savings: approximately 35%
    Material Savings: approximately 25%
    Notes: all columns, posts, floors, and railings preframed in the factory; all design & engineering already preapproved; no scraps, waste, nor mess, exterior surfaces ready for finish coat; amcorite unibody structural ferrocement skin acts as flashing and back flashing: no complicated waterproofing details required
    steptaskmaterial
    1consult drawingsam‑cor Field Manual
    2set labeled am‑cor balcony/porch panels (includes posts, railings)am‑cor Kit includes fasteners
    3enamel or coat with amcoriteenamel/amcorite, sand, cement
    4apply waterproofingwaterproofing
    5flash & seal at wall/roof edgesflashing & sealant
    steptaskmaterial
    1consult drawingsarchitectural or standard plan
    2consult codeposts, beams, joist spans
    3measure & cut posts & beamspressure treated wood
    4measure & cut floor joistswooden material
    5measure & cut deckingwooden material
    6frame & fasten joists, decking, posts, beamsbolts, hangers & fasteners
    7apply claddingAZTEK/fiberglass- wood
    8flash & seal at wall/roof edgesflashing & sealant
Total Labor Savings: approximately 55%
Total Material Savings: approximately 40%
Total Time Savings: approximately 30%
Total Estimated Savings
Dried-In Building Shell
am‑cor System
Ferrocement Prefab Kit
Standard Construction
Wood Stick-Built Framing
Steps to Complete: approximately 39Steps to Complete: approximately 76

Conclusion

The am‑cor Ferrocement Construction System is lighter, stronger, and faster and than Stick-Built Wood Framing construction, and is of superior durability and strength. Moreover, the am‑cor System’s overall integration allows for considerably faster & simpler construction, thereby lowering overheads and management costs.

Use of the am‑cor System provides a higher level of construction (fire, disaster, vermin resistance; greater security; ease of insulation and service installation) for a lower price.

Questions or comments? Please contact us.

Assumptions & Disclaimers

All figures are good-faith reasonable estimates under standard site & marketplace conditions and are calculated in US monetary, labor, and material units for common industry scenarios. All figures are estimates for the specified task or material only, and exclude supporting labor, materials, equipment and tools. Also excluded are taxes, cost of land, siteworks & utilities, construction management costs, fuel, electricity, transportation, etc. Figures assume no unusual site conditions, standard construction practices, generic building plan, etc. Overheads or standard costs of doing business are not included. Architect fees, Contractor fees, and siteworks costs are not included. Actual buildings may vary significantly per project and may not necessarily fall within the range of generic savings as calculated. Please note all figures are time & project sensitive and not binding in any way. Estimates of labor & material are time & project sensitive and will vary. Labor & material prices, fuel, utilities, & business overheads vary with each region, and vary with kit size and design. All content in this document is for general informational purposes only. Opinions expressed herein are solely those of am‑cor inc.


submit to reddit