Hello everyone, hopefully I can help shed some light on the BuildDeck System. For 90% of typical applications, this system should serve your crew and your wallet very nicely. Shipping and pricing is significantly lower, the forms are in many cases stronger and handling is easier. This is an addition to a long legacy of great performing ICF floor systems with a different approach. There may be some applications where it would make sense to use a larger cut to length system, but dollar for dollar this system is designed to make you more money. The goals in mind in designing this system were affordability, availability, usability and safety.
Affordability - This was designed as a modular system in an effort to provide shorter shipping distances for the end user. This product molds on the same machines as a standard ICFs from the same locations (additional locations to be added shortly) so it can be shipped with your BuildBlock ICF product. In studying other systems, molded in steel was identified as a cost prohibitive item that drives ICF floor system prices higher. By eliminating the molded in steel, the end user takes advantage of significant savings over competing systems. The bundles are approximately the same size as ICF bundles and therefore can be stored easily in smaller warehouses. Currently (as of 10/19/09, pricing subject to change) the BD-1000 (10" panel) retails to the general public at $9.95, the steel is $.54/ft.. This equates to approximately $2.75/sq. ft. for materials (at retail pricing!). Shoring will run $1.15 - $1.50/sq. ft. on your first job, and be reused on future jobs. Customers are currently seeing up to a 30%+ cost savings over other systems when materials and shipping are taken into consideration. Even if 10% of that savings is eaten up by interlocking the panels and assembling a few girders, I dont know a lot of contractors who would turn down an extra 20% profit.
Availibility - As mentioned above, the long-term plan for this product is to have availability from all BB manufacturing locations. This should shorten shipping for 90% of the country to less than 500 miles.
Usibility - This system is designed to be as functional as possible based on the design parameters. The 24" x 24" design is necessary from a manufacturing perspective. The trade off is a little more shoring. The 2 x 8 girders are built quickly and can be reused over and over. The 2 x 6 joists as well can be used again and again. At local Big Box Store prices (no contractor or bulk discounts) the materials for a 20' x 30' shoring system came out to around $750.00 (US). Because the shoring can be reused, this is pretty affordable, and significantly more affordable than commercially available systems.
This shoring system is recommended. As it was stated in an earlier post "EVERY SUSPENDED CONCRETE FLOOR SYSTEM AND THE SHORING FOR THE SYSTEM MUST BE ENGINEERED ON A PROJECT SPECIFIC BASIS." This merely shows a cost effective option to shoring for this system.
The steel is a 20 ga 2" x 2.5" x 2" C-channel. It fits snug over the arms on the BD and is very fast to install. An earlier post stated something about lack of strength in the arms. During testing, panels were spanned over 2 x 4's supported only by the two arms on the outside edges. These panels were then loaded with 1050 lbs. of weight per panel, and still did not fail. These panels are molded from virgin 1.5 lb. density EPS, just like ICF blocks, and are VERY strong whereas competing products are usually molded out of much lighter density foam, some using recycled material. This makes the BD system a bit more structurally capable than other systems. The steel is dimpled, so there is good adhesion between the concrete and the steel. For more support, 3.5" screws can be installed from the underside through the C-channel and foam to be enveloped by the concrete in the beam. By attaching the ceiling material directly to the concrete, you significantly increase the safety in seizmic and fire situations.
The C-channels are custom order and sold in bundles of 100 ft. (10 x 10' length). Being 2.5" wide, these also work great to cover our standard BuildBlock form interlocks during a pour or left in place on an ICF wall top to provide an easy to screed to surface. The steel is not included in calculations for strength in regard to shoring frequency. The steel could be replaced with heavier structural steel studs or custom steel T-beams if longer shoring frequency is desired. All things considered, the low cost of the panels and the shoring system combined with the low cost of this steel set-up make for a very affordable and functional floor system.
The self draining channels were added to prevent moisture buildup in the interior cores. If water gets trapped in the cores during the installation process, it can lead to mold and mildew in the ceiling below. These drainage holes eliminate the risk of costly damage to the structure. They are designed to accomodate any pitch and still drain properly from either side.
As with BB ICFs, the panels are numbered and lined on the underside for fast installation of cut forms. The interlocks connect securely and contribute significantly to the overall strength and safety of the system. The top has dovetail grooves to help the forms better adhere to the concrete. These will also facilitate the installation of rebar chairs currently in development.
Safety - The system is very safe. One installer noted that while setting steel (standing on top of the BD system with recommended shoring) that he felt a lot safer than he does standing on "Brand X". The system does not move around near as much and does not have near the amount of deflection. The steel C-channels in the beam bottom reinforce the panel so the installer does not fall through should a foot accidently land down in the beam channel. The shoring may seem like overkill, but regard for human life should never be taken lightly. There are many shoring methods that will work. In any case, they should be designed and approved by a professional trained in structural engineering.
All in all, the system was designed with installers in mind. At this price, you can't afford not to give it a try!
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