3.

2 ESTIMATING

Calculating Block, Concrete & Rebar

The following pages contain information on estimating block, concrete and rebar. An example plan with calculations can be found at the end of this section.

Block Estimation -- calculate types and sizes needed:

8 inch concrete core (fixed web)
q Standards q 90 corners q 45 corners q Top/Taper q Ends q Spacers

6 inch concrete core (fixed web)

q Standards q 90 corners q 45 corners q Top/Taper q Ends q Spacers

4, 6, 8, 10, 12 inch core (2-4-2 and Gblox panels)

q Panels q Webs q 90 corners q 45 corners

Additional block may be needed if your plans call for

q Gables q Pilasters q Buttress walls q Interior walls q Step footers q Numerous T-walls

3.2 ESTIMATING
Estimating 6 and 8 inch Core Fixed-Web Block
Ln 1* 1a* 2 3 4 5 6 7 8 8a 9 9a 10 10a 11 12 13 14 14a 15 16 Objective/Outcome Perimeter Find Wall Height Buildings wall sq ft Gross Blocks Square Footage of Openings Total Square Footage of all Openings Openings - Block reduction Net Blocks Number of 90 Corners Height of 90 Corners in ft Number of 45 Corners Height of 45 Corners in ft Total Number of 90 Corner Blocks Total Number of 45 Corner Blocks Number of Standard Blocks Total Number of Top Blocks Total Number of Standard Blocks Account for 3-4% waste For 90 Corner Blocks Account for 3-4% waste For 45 Corner Blocks Account for 3-4% waste For Top Blocks Account for 3-4% waste For Standard Blocks Operation ADD all sides SEE PLANS MULTIPLY Perimeter by Height DIVIDE Bldg wall sq ft by 4.0 Check plans and/or Window / door schedule ADD windows & doors sq ft to obtain total sq ft DIVIDE Total Openings sq ft by 4.0 SUBTRACT Openings from Gross Blocks See plans See plans See plans See plans MULTIPLY 90 Blocks per Corner by Number of Corners MULTIPLY 45 Blocks per Corner by Number of Corners SUBTRACT Corner Blocks From Net blocks DIVIDE Perimeter by 4.0 Minus Number of Corners SUBTRACT Top Blocks From Standard Blocks MULTIPLY Total 90 Corner Blocks by 1.04 ** MULTIPLY Total 45 Corner Blocks by 1.04* * MULTIPLY Total Top Blocks by 1.04 MULTIPLY Total Standard Blocks by 1.04 Line Reference Calculations

Ln 1 x 1a Ln 2 4.0

Line 4 Ln 5 4.0 Ln 3 - Ln 6

Ln 8 x Ln 8a Ln 9 x Ln 9a Ln 7- (Lns 10+10a) (Ln 1 4.0) (Lns 8 + 9) Ln 11 - Ln 12 Ln 10 x 1.04** Ln 10a x 1.04** Ln 12 x 1.04 Ln 13 x 1.04 Total 90 Corners: Total 45 Corners: Total Taper/Tops: Total Standards:

* In the case where your walls have different heights, you will need to do a separate estimating sheet for each section of a different height and add all estimates to calculate your total block needed. ** Round total number of corners up to an even number (corners are packaged and shipped in pairs. You should receive your corners in bundles packed lefts and rights. If not, please contact your local Greenblock representative. NOTE: All block will be rounded up to pallet counts/sizes. Check with shipping for counts.

3.2 ESTIMATING
Estimating short cut:
1. Calculate total wall sq footage (L x W x H minus square footage of windows and doors) 2. Divide by 4 for total block count 3. Count 90 degree corners on layout 4. Multiply number of corners times height (equals total 90 degree corners needed) 5. Repeat step 3 and 4 for 45 degree corners (equals total 45 degree corners needed) 6. Subtract corners from total block count 7. Divide total linear footage of layout by 4 to get subtotal top/taper blocks needed 8. Subtract number of corners in linear layout from top/taper blocks needed 9. Calculate total standards by subtracting from total block needed (ln 2), the 90s (ln 4), 45s (ln5), and the top/taper blocks (ln 8) 10. Add 3-4 % to the standards for waste

Estimating Panels
A. Use the estimating sheet found at the end of this section to calculate the required quantities of each type of block required to complete your job. B. Multiply the total from line 16 (Total Standards) by 2 to determine required panels. C. Multiply the total from line 16 (Total Standards) by 8 to determine required webs. - Webs are available in 4, 6, 8, 10 or 12 inch core sizes. D. Estimating corner block for the panel systems. - The 4 inch panel system utilizes corners specific to that size. - The 6 and 8 inch panel system utilize corners from the fixed 6 and 8 inch systems. - Persons using the 10 & 12 inch panel system will need to miter the corners. E. Estimating taper/top block for the panel systems. - Not available in the 4, 10 or 12 - The 6 and 8 inch panel systems utilize tapers/tops from the fixed 6 and 8 inch systems. Reminder: All block will be rounded up to pallet counts/sizes. Check with shipping for counts.

3.2 ESTIMATING

Concrete Estimation

Use this basic chart for concrete calculations. Please be sure to follow the steps. Use the following for Line 6: (4 core - 81, 6 core - 54, 8 core - 40, 10 core 32, 12 core 27) Ln 1 2 3 Objective/Outcome Perimeter Gross Wall sq ft Openings sq ft Operation ADD all sides MULTIPLY Perimeter by Wall Height ADD each window and door sq ft to obtain total sq ft SUBTRACT Openings sq ft from Gross Wall sq ft Add corner blocks* and Subtract 1 sq ft per corner block from Net sq. ft. DIVIDE Final Wall Net sq ft by ?? sq ft Ln 2 - Ln 3 Ln Ref Calculations

Net Wall sq ft

Corner Adjustment (Final Wall Net Sq ft) Yards of Concrete Needed

Ln 4 - ?

Ln 5 ??

An easy way to determine how many corner blocks you have is to count how many corners there are and multiply that amount by the wall height. If you have variations in wall heights do each wall height as a separate section.

Rule of thumb concrete estimating method:

4 core 1 yard of (multiply 6 core 1 yard of 8 core 1 yard of 10 core - 1 yard of 12 core - 1 yard of concrete per L X H of wall concrete per concrete per concrete per concrete per 81 Wall sq. ft. and divide by 81) 54 Wall sq. ft. 40 Wall sq. ft. 32 Wall sq. ft. 27 Wall sq. ft.

3.2 ESTIMATING
Alternate Rule of thumb:
4 core - 1 yard of concrete for every 20 forms installed 6 core - 1 yard of concrete for every 13 forms installed 8 core - 1 yard of concrete for every 10 forms installed 10 core - 1 yard of concrete for every 8 forms installed 12 core - 1 yard of concrete for every 6 forms installed Calculate amounts of concrete needed by using the Final Wall Net Square Footage (Line 6). We recommend you double check your figures for concrete amount needed or have your supplier do so NOTE: Check with your local supplier for aggregate and any slump/ trucking requirements. Greenblock recommends: Minimum 2500 PSI 4.5 - 6.5 slump delivered Pea gravel ( aggregate) for: 4 and 6 cores NOTE: Larger rebar size and/or volume may require smaller aggregate for proper concrete placement and consolidation

3.2 ESTIMATING

Rebar Estimation
Rebar reinforcement within concrete walls reduces cracking and buckling under different building loads (i.e. backfill, wind, etc) and helps manage cracking caused by temperature swings. Properly installed reinforcement around doors and windows is imperative for the buildings structural soundness. Footing/slab dowels are often spaced every 24 inches, with a minimum of 2 horizontal rows in the footing or thickened slab. You will need to estimate the necessary rebar for required steel placement determined by codes or engineering.* Horizontal wall rebar should be inserted as required during placement of the block in each course. Make certain you lay it with the correct overlap lengths, normally 40 times the bar diameter. As each course with horizontal rebar is laid, if possible offset it to the previous course. Continue alternating the rebar this way for the entire structure.* Lintel steel needs to be positioned above doors and windows to support the load over these openings. Lintel rebar depends on many factors and should be calculated by an engineer or taken from PCAS Prescription Method; or to local codes.* Vertical rebar should be installed only after all courses and horizontal rebar have been laid. Dont forget to put vertical rebar under the windows and within 6 inches of both sides of each opening. Check codes for vertical rebar specifications for below and above grade building. (In the rare case local codes require the vertical rebar be tied to the footing/slab dowels - use 4 ft. to 5 ft. lengths, dropping the block over the rebar.)* If another story is to be constructed, be sure to install connecting vertical rebar. Check local codes or engineering specs for height requirements * All rebar placement should be calculated to local codes, ACI 318, PCAs Prescriptive Methods for ICF Residential Construction or engineers specifications.

3.2 ESTIMATING

Example Plan

Disclaimer: These estimations are given solely as an example of how to figure amounts of block, concrete and rebar for your project. Actual specifications should be provided by approved engineering tables, local codes, or the site engineer.

Figure 1

Example Layout

(for demonstration purposes only)

From our example plan we can calculate the following: _____Perimeter 148 linear feet _____Exterior walls 9 feet high _____Two 30 doors (21 square feet each; 42 square feet total) _____Eight 4x 3 windows (12 square feet each; 96 square feet total) _____Eight 90 corners

3.2 ESTIMATING

Rebar Estimation
Assume:
Number 4 rebar, 20 foot sticks Vertical overlap between floors is 24 inches Horizontal overlap is 20 inches (HINT: 4 webs) Vertical spacing for dowels and rebar is 20 inches

Calculate Horizontal rebar

_____ _____ _____ _____ _____ _____ _____ _____ _____ _____ _____ _____ _____ _____ _____ _____ _____ _____ _____ _____ _____

Calculate rebar needed per row in 1 course (be sure to include required overlaps) multiply that times rows or horizontal rebar needed.

Perimeter 148 linear feet or 1776 linear inches Using 20 ft. sticks and 20 inches overlap = each stick will span 184 or 220 inches 1776 (perimeter linear inches) by 220 inches (each bars span) = 8.07 rebar required per row 9 courses +1 extra rebar bottom course +1 extra rebar top course =11 rows needed at 8.07 rebar per row = 89 - 20 foot rebar sticks needed or 1780 linear feet Doors add one extra bar over each door To extend 24 inches either way for overlap Therefore each extra rebar will be 84 inches (36 + 24 + 24) 2 30 doors = 2 x 84 inches = 168 inches 12 = 14 linear feet Windows one extra bar over each window (8 48 inches x 36 inches) 8 x 48 inches = 384 inches add 24 inch overlap each side x8 windows = (48 inches x 8) = 384 inches 384 inches + 384 inches = 768 inches 12 = 64 ft. Footer calculate footer rebar requirements Vertical Calculate height of walls times spacing. If this story is top story, rebar should be cut 3 below top of block. If this is a connecting story rebar needs to be cut for connection to next level.

ADD:

Footers Horizontal Windows Doors Vertical Waste 3%

as required 1789 64 14 900 2767 83

Rebar needed for example

2850 Linear Feet

3.2 ESTIMATING

Concrete Estimation
Greenblock 6 inch Fixed Web:
_____Approximately one yard of Concrete for every 54 square feet of wall _____Calculate amount of concrete needed by using the Net Wall Square Footage TIP: It is recommended that you double check your figures for concrete amount needed or have your supplier do so.
Ln
1

Objective/ Outcome
Perimeter

Operation
ADD all sides MULTIPLY Perimeter by Wall Height ADD each window and door sq ft to obtain total sq ft

Ln Ref

Calculations
20+10+14+20+14+10+20+40=148

Gross Wall sq ft

148X9 = 1332

Openings sq ft

96+42 = 138

Net Wall sq ft

SUBTRACT Openings sq ft from Gross Wall sq ft

Ln 2 Ln 3

1332-138 = 1194

Corner Adjustment (Final Wall Net Sq ft)

Add corner blocks* and Subtract 1 sq ft per corner block from Net sq. ft.

Ln 4 / 54

1194 / 54 = 22.11

22.11 Yards of Concrete Needed

NOTE: Check with local supplier for aggregate and slump /trucking requirements.

3.2 ESTIMATING

Blank Estimation Worksheets

Ln 1* 1a* 2 3 4 5 6 7 8 8a 9 9a 10 10a 11 12 13 14 14a 15 16 Objective/Outcome Perimeter Find Wall Height Buildings wall sq ft Gross Blocks Square Footage of Openings Total Square Footage of all Openings Openings Block reduction Net Blocks Number of 90 Corners Height of 90 Corners in ft Number of 45 Corners Height of 45 Corners in ft Total Number of 90 Corner Blocks Total Number of 45 Corner Blocks Number of Standard Blocks Total Number of Top Blocks Total Number of Standard Blocks Account for 3-4% waste For 90 Corner Blocks Account for 3-4% waste For 45 Corner Blocks Account for 3-4% waste For Top Blocks Account for 3-4% waste For Standard Blocks Operation ADD all sides SEE PLANS MULTIPLY Perimeter by Height DIVIDE Bldg wall sq ft by 4.0 Check plans and/or Window / door schedule ADD windows & doors sq ft to obtain total sq ft DIVIDE Total Openings sq ft by 4.0 SUBTRACT Openings from Gross Blocks See plans See plans See plans See plans MULTIPLY 90 Blocks per Corner by Number of Corners MULTIPLY 45 Blocks per Corner by Number of Corners SUBTRACT Corner Blocks From Net blocks DIVIDE Perimeter by 4.0 Minus Number of Corners SUBTRACT Top Blocks From Standard Blocks MULTIPLY Total 90 Corner Blocks by 1.04 ** MULTIPLY Total 45 Corner Blocks by 1.04* * MULTIPLY Total Top Blocks by 1.04 MULTIPLY Total Standard Blocks by 1.04 Ln 8 x Ln 8a Ln 9 x Ln 9a Ln 1 x 1a Ln 2 4.0

Estimating 6 inch and 8 inch Core Block (Call to estimate panel systems)
Line Reference Calculations

Line 4 Ln 5 4.0 Ln 3 - Ln 6

Ln 7- (Lns 10+10a) (Ln 1 4.0) (Lns 8 + 9) Ln 11 - Ln 12 Ln 10 x 1.04* Ln 10a x 1.04* Ln 12 x 1.04 Ln 13 x 1.04 Total 90 Corners: Total 45 Corners: Total Taper/ Tops: Total Standards:

* In the case where your walls have different heights, you will need to do a separate estimating sheet for each section of a different height and add all estimates to calculate your total block needed. ** Round total number of corners up to an even number (corners are packaged and shipped in pairs. You should receive your corners in bundles packed lefts and rights. If not, please contact your local Greenblock representative. NOTE: All block will be rounded up to pallet counts/sizes. Check with shipping for counts.

3.2 ESTIMATING
Concrete Estimation for 6 core block*
Ln 1 2 3 4 5 Objective/Outcome Perimeter Gross Wall sq ft Openings sq ft Net Wall sq ft Yards of Concrete Needed Operation ADD all sides MULTIPLY Perimeter by Wall Height ADD each window and door sq ft to obtain total sq ft SUBTRACT Openings sq ft from Gross Wall sq ft DIVIDE Net Wall sq. ft. by 54 sq. ft. Ln Ref Calculations

Ln 2 Ln 3 Ln 4 / 54

Concrete Estimation for 8 core block*

Ln 1 2 3 Objective/Outcome Perimeter Gross Wall sq ft Openings sq ft Operation ADD all sides MULTIPLY Perimeter by Wall Height ADD each window and door sq ft to obtain total sq ft SUBTRACT Openings sq ft from Gross Wall sq ft DIVIDE Net Wall sq. ft. by 40 sq. ft. Ln 2 Ln 3 Ln 4 / 40 Ln Ref Calculations

4 5

Net Wall sq ft Yards of Concrete Needed

Substitute sq. ft. on line 5 above with the following to obtain: 81* for the 4 inch core system 27* for the 12 inch system For 8 Core block Horizontal below and above grade requirements for 8 concrete core blocks can be found by checking with national or local codes (ACI 318), engineering or PCAs Prescriptive Method for Insulating Concrete Forms in Residential Construction. Add 1% to 2% waste. For All Other Core blocks Check your engineering and/or local codes. Add 1% to 2% waste.

3.2 ESTIMATING

Crew and Labor Estimating

Building with Greenblock requires:
Less manpower than most other types of construction Less labor than most of our ICF competitors

A good working size crew for a residential home might include:

One qualified carpenter Two to three laborers

Larger jobs will be finished quicker with larger crews. It helps if someone has minimal experience with concrete, but it is not mandatory. Fixed web systems:
In general, a good building rate for a 3-4 man crew is approximately 15 forms each per hour. _____15 forms of 6 inch = 60 square feet (15 x 4.0) _____15 forms of 8 inch = 60 square feet (15 x 4.0)

Panel Systems:

In general, a good building rate for a 3-4 man crew is approximately 12 forms each per hour. _____12 forms of 4 inch = 48 square feet (12 x 4.0) _____12 forms of 6 inch = 48 square feet (12 x 4.0) _____12 forms of 8 inch = 48 square feet (12 x 4.0) _____12 forms of 10 inch = 48 square feet (12 x 4.0) _____10 forms of 12 inch = 40 square feet (10 x 4.0) Calculations include cutting and bending rebar, installing alignment systems, building and installing window and door bucks. Therefore a 3000 gross wall square foot structure may possibly require: _____62 hours labor for 6 inch panel system _____50 hours labor for 8 inch fixed web system Additional floors, gables, T-walls, and 45 corners may reduce overall productivity and slightly increase construction times. TIP: Contact your local Greenblock representative for help during your first estimate, build and pour.

Tip!