Concrete Rib House - Complete

CONCRETE RIB HOUSE - Eugenio Aburto, AIA - 760 610 10651
TABLE OF CONTENTS
INTRODUCTION PG 2
CONCRETE RIB HOUSE A CASE STUDY PG 5
TALKING MONEY – COST STUDY OF BUILDING CONCRETE RIB HOUSES USING SPREAD SHEETS PG 23
• FONDATION COST PG 25
• IWALLS COST PG 30
• ROOF COST PG 45
• BEARING AND PARAPET BEAMS COST PG 58
CONCLUSION: SHELL COST PER SQUARE FOOT PG 63
ARCHITECTURAL SOLUTIONS FROM THE CASE STUDY CONCRETE RIB HOUSE PG 2
FLOOD HAZARD AREAS THE FLOATING MEZZANINE SOLUTION WITH CRH SYSTEM PG 80
LIVE AND WORK CONDOMINIUMS USING CRH SYSTEM, A SOLUTIONTO ENERGY CONSERVATION PG 96
POUTPOURRI OF SAMPLES PHOTOS OF MASONRY CONCRETE HOUSES PG 105
MASTER PLANS WHERE TO BUILD WITH CRH SYSTEM PG 112
RAMMED EARTH HOUSES HOW THE CRH SYSTEM WAS BORN PG 117
CIUDAD AZTECA – 7,500 HOUSES BUILT IN 15 MONTHS, 8 SCHOOLS, SHOPPING CENTER, OFFICES PG 129
COSTA BANDERAS AN INVESTMENT AND RETURNS FOR A PLANNED RETIREMENT DEVELOPMENT PG 137
ABOUT THE AUTHOR PG 151
GENERAL INFORMATION PG 155

The fast growing population is changing living conditions for people.
Land cost are forcing people to live in zones of high risk. The news often is about dwellings destroyed by natural
disasters such as: fire, hurricanes, tornados, flooding, or earthquakes. Such destruction can be possible
because the traditional construction system used, wood framing, is out of date to protect structures subject to the
conditions in the lower cost areas where land is being developed.
After years of experience designing and building in harsh environments with strict budgets, and after living in the USA
and reading the newspapers about the destruction of homes by nature, I decided to perform a case study to show
a house capable of resisting the calamities described in the news. This book describes my Concrete Rib House
(CRH) construction system. The CRH is durable, capable of resisting natural disasters with an affordable budget
and in compliance with desired conditions of thermal performance. It uses regional materials. Construction with
poured-in-place concrete minimizes the use of timber resources.
Before talking about CRH, let me analyze the cause and effect of such natural disasters.
• FIRE.- Traditional construction systems based on the use of flammable materials in the exterior envelope are
vulnerable to attack by burning embers. Plaster on the walls is not enough protection; embers go through
openings and find places to start new fires, especially with the help of strong winds generated by topography or by
weather conditions. News photos frequently show only the fireplace or other masonry element remaining in a
burned house.
• HURRICANES and TORNADOS.- The tradition of building houses with wood framing produces light structures;
the roofs are easily lifted off by strong winds. Eaves catch the wind and the horizontal wind pressure against the
windward side of the structure pushes the roof; on the leeward side, where there is no pressure, a vacuum is
created; these forces working together can lift the roof off the walls. Without the roof, there is no bracing for the
walls; result: the total structure collapses.
• FLOODING.- Strong precipitation by itself or accompanied by hurricanes is factor for devastation. The flooding
affects the wood framing, warping and damaging the structure, and rusting nails and other metal fasteners.
Additional problems during flooding, such as destruction of utilities, lack of drinking water and lack of power are
subjects which will be discussed in detail in the section of this book showing design solutions.
• EARTHQUAKES.- Nobody knows when or how strong an earthquake will be. The typical construction solution to
earthquake danger in wood framing is to reinforce corners with plywood to take the shear stress. Plywood, as a
material based on a natural resource, cannot guarantee consistent quality control. This leaves a wooden
structure vulnerable to seismic events.
• MOLD AND TERMITES.- Again tradition is stronger than logic, dwellings built with wood framing are good to
attract this pest.
INTRODUCTION

In this book I will talk about the building solutions to avoid the damage of natural disasters described above
using CRH the construction system developed by me during many years of general experience in architecture
and building. I have constructed several thousands of dwellings of one and two stories, schools, commercial
buildings, hotels, and offices using this system. It is based on the Romans old technique - concrete poured in
place. Such a technique was used more than 2,000 years ago, with many Roman structures still standing.
Below is a condensed description of solutions to the devastating effects of natural disasters. Details, with text
and graphics, are discussed later in this book.
FIRE.- Foundation, walls and roof are all poured-in-place concrete. This structure has no exposed flammable
materials. For additional protection window and door openings can have an automatic system of metal curtains.
HURRICANES and TORNADOS.- The CRH system is designed to have all its elements supported by rigid
pinned connections; together the foundation, walls and roof form a monolithic box structure of heavy weight.
The house can have eaves and gable roofs and still keep its cohesion under strong wind forces.
FLOODING.- Concrete and Styrofoam are not affected by moisture. In severe flood hazard zones the interior
face of the walls will have stucco covering instead of the gypsum board used in CRH in other areas. The
Design Solutions section in this book has further information.
EARTHQUAKES.- An advantage of working with concrete is that there is advanced technology in structural
calculations to determine the quality and stress resistance necessary for the structure to respond to specific
seismic conditions. Additionally, the CRH structure uses the T-beam concept for walls and roof, arranged in
such a way that the structure is braced in the “x” and “y” directions.
MOLD and TERMITES.- Concrete has no organic composition for mold; and termites don’t eat concrete.

Besides being the solution for natural disasters, the CRH construction system has an economic benefit; the CRH
can create jobs.
CRH produces houses in a massive manner. The system is so simple that it uses many unskilled workers who with
a little training become highly productive. The big volumes of construction materials make room for negotiated
prices – massive construction is the key for lower construction cost and good profits. Payrolls and materials
purchases make the money flow; low house prices increase sales; homeowners need new furniture and
accessories; moving companies are busy; cities receive building permit and property tax revenues; offices, stores,
factories, and many other businesses will need to hire more employees. People related to the development
business using CRH have income and buying power. The economy goes rolling.
This book will show how the CRH system can be used to build with crews of unskilled workers, in a fast mode.
Concrete can be customized according to structural and budget needs; it can be molded to create any architectural
decoration element to satisfy the demands of market trends. Builders can build fast, developers can sell fast,
perhaps with small profits per unit but much more often.
The case study was built in the Coachella Valley of Southern California (near Palm Springs), chosen considering its
very high and low temperatures and its location close to the San Andreas Fault, to test power savings and
earthquake structural advantages.
After showing the construction process, a cost study based on the information logged during the construction
process will be analyzed. Several examples of design based on the case study, samples of conceptual design of
large and small dwellings, some solutions for flooding areas, and design proposal for live-and-work units will be
shown. To complement, some site planning samples, one with investment and profit projections, are included from
my professional work.
Lastly the book includes an appendix with my experiences in search of a construction system for massive
production, from prefabrication, rammed earth, masonry concrete houses, schools, and a multistory hotel.

CONCRETE RIB HOUSE
A CASE STUDY
The system is simple, similar to structures built by the Romans using puzzolanas (natural cement of
volcanic origin) concrete. Their structures have stood for millennia and today are tourist attractions.
The CRH system is similar to that of the Romans but has been updated with today’s technology, new
materials, and structural engineering.
The Romans used brick walls as formwork. I used plywood panels for the case study and blocks of rigid
foam as formwork and insulation. Plywood could be replaced by metal or fiberglass panels to achieve a
more sustainable and longer lasting formwork, avoiding use of trees to support the green building
movement.

THE CONCRETE RIB HOUSE
Why concrete, why ribs…?
Because the concrete structure resisting loads and stress in this house is similar in function to the ribs protecting the main
organs of some living creatures, including humans. The concrete ribs produce a building structure highly resistant to natural
calamities such as earthquake, fire, hurricane, cyclones and flooding. Concrete is not attacked by termites or mold.
In both walls and roof, the spaces between the ribs are filled with rigid foam insulation. 13 inches of this material provides
an R value of 54.21. There are no leaks because the insulation is embedded in the concrete.
Foundation. This is similar
to a customary foundation in
conventionally framed
houses.
The difference is that
steel dowels are set in
the footings to anchor
the walls. These dowels
function to receive the
reinforcement of vertical
ribs. Note the reinforcement of the stems attached to
the dowels and preparation to hold roof T-beams
upper and lower re-bars, as well.

WALLS
The structural concept of the Concrete Rib Houses
is based on the T-beam shape used to handle large
spans with a minimum of concrete and steel
reinforcement. The T-beam name is because its
shape is a sort of capital T. The stem of the “T” would
be the rib, and the crossbar of the “T” would be the flange.
I use T-beams in the vertical position to create walls.
For the sake of simplicity, I have not shown the steel
reinforcement in the illustration at left. Two T-beams
in the same line and touching creates an alcove where
the insulation is embedded. The flanges in a wall
create a diaphragm to resist shear stress. The
insulation functions as formwork for the sides of the
ribs and at the back of the flange.
T-BEAM
T-BEAMS
ALCOVE

The sketch at the left shows one ribbed wall supporting and connected to
the roof T-beam. This connection creates bracing between walls and
improves the structural capacity to resist forces such as wind pressure or
earthquakes. The architectural design is done to have T-beams of walls
and roof in “x” and “y” directions to have bracing in all walls, keeping the
“concrete box” concept unique in CRH system.
Finally this sketch shows two vertical contiguous beams which
create the alcove where the rigid foam insulation can be seen.
The diagram shows the poured concrete walls with the embedded
insulation. This system makes the insulation more effective
because there are no leaks or voids, such as typically occur with
insulation material installed between wood or metal framing.
This concept is applicable to walls and roof.
ROOF T-BEAM STEM
ROOF T-BEAM FLANGE. ROOF SLAB
T-BEAM IN VERTICAL
POSITION CREATES THE
WALL
EXTENSION OF
WALL FLANGE
POURED WITH
THE ROOF
RIGID INSULATION

The construction process is shown in
the photo at right. Note the dowels
and the preparation for plumbing and
electrical which are set in trenches
under and through the footings and
floor slab.
The photo at left shows the vertical reinforcement of the ribs being
attached to the dowels, for a T-beam wall with embedded insulation.
The 3 types of walls used en this system are described on the next
page.
FOUNDATION
ELECTRICAL
PLUMBING
DOWEL
RIB
REINFORCEMENT
ATTACHED TO
DOWEL

WELDED WIRE MESH USED AS
REINFORCEMENT FOR THE DIAPHRAGM
RESISTING SHEAR STRESS
WALL CONSTRUCTION
The CRH uses three types of walls:
• Type 1.- Exterior T-beam walls with embedded insulation, width per design depending of R value desired.
Can be bearing or no bearing.
• Type 2.- Exterior or interior walls. 6” thickness for bearing, 4” thickness for non-bearing.
• Type 3.- Partition walls: steel framing, studs size per design.
A picture of the welded wire reinforcement,
and the wood forming behind.
ROOF STEM
REINFORCEMENT
WALL RIB REINFORCEMENT

At right is shown the
electrical preparation on
the wood forming.
Above: forming of several walls in progress.
Above is the rigid foam insulation in place. Note the
ties in place ready to receive the forming of the
opposite side of the wall. The efficiency of the thermal
insulation is the result of having not leaks or voids in
between the construction elements.
WALLS – continued

Insulation in all required walls following the building plans as lines drawn on the slab by the forming crew.
After placement of insulation, reinforcement and forms, the concrete is poured to the top of the walls.
WALLS – continued
The next step is placing the rigid insulation following the previously marked location of the walls, as shown
below (top left). The other sketches show the sequence of setting insulation and pouring walls.

At left
exterior
view of rigid
insulation
showing
electrical
ducts which
will be
embedded
in concrete.
Above interior view insulation covered by
interior forming. Note the reinforcement
for the roof stems .
At left is a detail of dobies serving to hold
the insulation as well keep the diaphragm
at the thickness required by the structural
calculations.
Photo sequence of setting insulation

At left: Once the forming has been finished, the
next step is pouring the walls with premix
concrete delivered by pumping. This picture
shows the pouring of the walls all the way to the
top. Note the steel reinforcement to be used for
the parapet walls, which will be poured later at
the same time as the roof structure.
At the lower left of the picture a window is shown
set in place. When the walls are poured, the
window will be held by concrete. The efficiency
of the thermal insulation lies in eliminating leaks
or voids in between the construction elements.
The picture at right shows the removal of the forms
and the surface on the face of the wall. This wall is
an interior bearing wall 6” thick, which will carry T-
beams in the direction of the re-bars.
The T-beams on top of the area behind the opening
will be north-to-south. These will combine with east-
west axis beams to provide the greatest earthquake
resistance.
Pouring walls

Roof - diagrams of placing insulation and pouring concrete
Note that supports holding the blocks of rigid insulation and the reinforcement of the
ribs (flanges) are not shown. These can be seen in the first photo on page 16.
Fast setting pre-mix concrete is placed by pump, as shown in the photo on page 17. Fast setting concrete is
used to enable the roof forms to be removed quickly, to expedite further phases of the construction such as
applying the gypboard and building the partition walls.

The forming to pour the roof is special because it is
not necessary to form the entire bottom of the roof
area. It is only necessary to support the bottom of the
stems of the T beams which also serve to support the
rigid insulation. These supports are lumber strips
which are held up by vertical adjustable-height steel
posts.
At left the worker is adjusting a piece of insulation to
be set. Above right is a photo of an opening for a
skylight. Note the reinforcement and the metal nailers
that will hold the ceiling gypsum board. Also note the
T-beams set at right angle directions to work bracing
each other.

Pouring the roof using pre-mix concrete set by pump.
The roof pouring was done by a crew of 4 men on the roof plus
one on the ground controlling the pump. They poured 2,200
square feet of roof in one day.
Forming posts and beams
were previously placed, and
the rigid insulation and the
stems steel rebar
reinforcement done. Note
that these T-beams are
meant to work as bracing in
one direction (east to west in
this case). The T-beams on
top of the area behind the
opening will work as bracing
at a right angle (north to
south). This design gives
the most resistance to
earthquakes and wind
pressure.

The savings in labor makes the Concrete Rib
House system very competitive, and the strictly
controlled quality delivers a great product.
In the photo above a stem is visible at the edge of an opening for a
sky dome, as well as the bottoms of stems between the rigid
insulation. The centers of the stems have a steel stud embedded
which will be used to attach the gypsum board for the ceiling. A
similar solution is used in the center of the ribs in the walls for
attaching the gypsum board wall finish. This enables the builder to
meet the expectations of the market regarding the appearance and
use of walls. The difference between this and a stick-built house will
become apparent only during a fire when the CRH does not burn, or
during a tornado when the roof does not blow away.

Living room
Master bedroom
Interior final appearance

kitchen Granite counter

1. Access path to the main
entry.
2. Side yard entry court; note
the corner window.
3. The casita separate entry.
Patio with special fabric shaded trellis
creates a relaxed atmosphere to enjoy
the landscape and entertain friends. To
increase fire resistance the columns
and trellis can be built with vinyl
elements, which will melt but will not
create flames.
No exterior surface of the house is
flammable; contents such as
memorabilia and furniture will be safe.
1 32
Exterior appearance

Concrete Rib House at night
At night the house is vibrant in the dark. The
owners of this house will sleep with no worries of
earthquakes, fires, hurricanes, tornados, or other
natural disasters. They are protected by the rib
structure built with concrete as used around 2,000
years ago by the Romans whose structures still
stand today as tourist attractions.
Concrete is a material which allows strict quality
control since the technology permits calculation of
the strength required according to function,
environmental circumstances and budget. Wood,
as a natural product, does not offer the same
control.
The case study
shows a house in the
Desert Modern style,
but this construction
system easily
accommodates any
architectural style.
Refer to the potpourri
of samples section.

TALKING MONEY: A cost study of building Concrete Rib Houses
$The greatest economic success in building houses using the Concrete Rib House
method occurs when multiple units are produced with the same set of formwork.
This cost study assumes 40 uses of one set of formwork, and will show a great
competitive value, considering the high quality of the building structure. The prices
used in this study are actual cost in California in the year 2007, the construction year
of the CRH case study. Costs are generated using the logged prices for materials
and labor.
The labor costs unique for the CRH were established by observation of the time
required for each task and using the workers’ hourly rates. In the case of processes
common to conventional construction (for example foundation and stucco finish) the
cost was negotiated at local market rates.
The cost shown in the study are not marked up and do not include profit, taxes,
worker insurance, travel expenses.

PROCESS TO OBTAIN UNITARY COSTS
On the following pages you will find spread sheets for the basic elements to build a structure with the CRH method.
The studies by experience by building the case study have green headers. The ones related to conventional
construction: yellow and light blue headers.
When referring to structural conditions, you will find structural drawings with floor plans, details, sections, as
required for information.
The cost studies are only for basic elements to build by CRH method, finishing materials (flooring, stucco. paint, as
a sample), plumbing including kitchen and bath fixtures, electrical, air conditioned and other special materials or
installations will be per market values.
The basic costs for the CRH shown are:
•FOUNDATION - The foundation of the CRH is done as in conventional construction, except for the use of
dowels to receive the structural reinforcement for the exterior walls.
•WALLS - This phase of the construction is one of the basic elements of CRH method.
•ROOF - This phase is also a basic element of CRH method.
Foundation, walls and roof are the core which makes the CRH method capable of resisting natural disasters.
Finishing, equipment and appliances are as required by specifications, market costs.

FOUNDATION
• The cost study is based on the experience when building the CRH case study.
• Page 26 shows the construction foundation floor plan of the CRH case study.
• Page 27 has the structural construction details depicting dimensions and reinforcement obtained by structural
calculations in compliance with the governing codes and regulations of the City of Cathedral City.
• Page 28 and 29 show spread sheets template using the information contained in pages 26 and 27.
• The labor was provided by a concrete contractor working at a flat fee using his own equipment.
• The material was bought as a separate item.

FOUNDATION FLOOR PLAN

FOUNDATION STRUCTURAL DETAILS

Table headers, yellow fill, calculations to find volume of concrete required:
axis – Letters correspond to labels of the axes on the floor plan on page 26.
between – Axis segment is located between the axes at right angles. See floor plan on page 26
type - Detail of foundation with dimensions and reinforcement required by details shown in sheet S3 on page 27.
base in - Dimension of the base from sheet S3 on page 27 by detail type.
height in - Dimension of the height from bottom to finish floor as shown sheet S3 page 27. by detail type.
area in2 - Area of the foundation section in square inches (the product of Base by Height).
length ft - The length dimension in feet and inches, per sheet S2 page 26.
length in - The translation of the length from feet and inches to inches.
volume in3 - The volume in cubic inches as the product of Area square inches by Length inches.
volume CY - The volume in cubic inches divided by 45,656 (cubic inches in a cubic yard) to convert the cubic inches
to cubic yards as used to order premix concrete
Table headers, blue fill, calculations to find the re-
bars for reinforcement, as noted in details sheet S3:
rebar - Specifications of the re-bar type per diameter,
and number of re-bars called in the details on S3 for
reinforcement.
length in – Total length in inches of re-bars
reinforcement.
pc of 20ft – Quantity of 20-foot re-bars, as commercially
available in the market. The length in divided by 240
(12*20).
FOUNDATION COST

•Table above left: dowels as shown in details on S3 – page 92.
•Table above right, shows area calculations of the areas shown in
sheet S2 on page 91.
•Table lower right is the total of materials and labor required to
build the foundation footings and floor slab for a house such as the
Concrete Rib House depicted in this book. The unitary costs are
as California Market in 2007. For updating use current costs in the
location of the construction site being studied.
FOUNDATION COST

WALLS
In the case study of the Concrete Rib House different wall types were used, according with their function. For
locations of each type, refer to floor plan S4 on page 31 and structural details on page 32.
•T-WALL TYPE A (see detail 1 on Sheet S5 on page 32) – This wall has a shape of a T-beam but in
vertical position, the stem of the T is named in here “Rib” because its protective function and its use
define the why the Method is named Concrete Rib House. The Ribs and the diaphragm slab encased
the rigid insulation, used by blocks in the dimensions required by design. The Rib end hold metal
nailers which let attach drywalls panels. These walls are used at exterior perimeter locations for living
areas. This cost study is for 16 inches wall thickness. Exterior walls can be any thickness weather
conditions and or budget will be decision factors.
•UNRIBBED WALL TYPE B (see detail 2 on page 32) – This walls have a rectangular foot print. Are
used to enclose no living areas, or in locations not exposed to the exterior at living areas. Normally are
used for bearing load walls, but can be partition walls. The face to have gypsum board panels will be
have encased metal nailers. This cost study is for 6 inches thickness.
•WOOD OR METAL FRAMED WALL TYPE C (see detail 3 on page 32) – Partition walls at market
cost.
The cost study will analyze the formwork used for A and B wall types. Items to hold wallers can be use over 40
times, but in the cost 40 times is the factor. The snap ties type are specific for the wall thickness. Cost of
stucco, nailers, gypsum board, insulation, concrete, pumping and labor included in wall type A. Wall type B
includes the same except insulation, gypsum board and or stucco only when specified. The costs have different
values for such variances.

FLOOR PLAN SHOWING WALL TYPES

STRUCTURAL DETAILS 1, 2, 3 FOR WALLS

The formwork material
and labor cost is the
same for any thickness
of wall. What defines
the wall thickness are
the dimensions of the
ties used. In this study
6” and 16” ties will be
considered.
$ 1.40
Cost per use when used 40 times, lineal
foot of wall 8 feet height
$ 28.10Cost per use when used 40 times, 20 ft wall
$ 1,123.9520 ft FORM WORK TOTAL COST
16.0016.00hours helper, assisting carpenter1
20.0020.00hours carpenter making formwork1
4.862.43stakes from 2x4x8'2
1.400.143' washer pin-100 in a box10
2.000.10red shot20
12.123.03bracing 2x4x10'4
14.582.43footing plates 2x4x8'6
72.723.03walers 2x4x12'24
204.004.25Jahan "C" bracket buy48
212.402.95Jahan "A" bracket buy72
53.12sales tax
6.75fuel subcharge
$ 504.0050.403/4" bb plyform 4x8 shts HUB price10
TOTAL
UNITAR
Y PRICE
DESCRIPTIONQ
STUDY TO SET COST OF FORMING PER LINEAL FOOT
$ 1.40
Cost per use when used 40 times, lineal
foot of wall 8 feet height
$ 28.10Cost per use when used 40 times, 20 ft wall
$ 1,123.9520 ft FORM WORK TOTAL COST
16.0016.00hours helper, assisting carpenter1
20.0020.00hours carpenter making formwork1
2.000.10red shot20
12.123.03bracing 2x4x10'4
14.582.43footing plates 2x4x8'6
72.723.03walers 2x4x12'24
204.004.25Jahan "C" bracket buy48
212.402.95Jahan "A" bracket buy72
53.12sales tax
6.75fuel subcharge
$ 504.0050.403/4" bb plyform 4x8 shts HUB price10
TOTAL
UNITAR
Y PRICE
DESCRIPTIONQ
STUDY TO SET COST OF FORMING PER LINEAL FOOT
FORMWORK COST

There is an additional cost of forming
material used to hold the formwork to the
concrete floor slab such material is per
use.
$ 0.48Cost lineal foot of wall 8 feet height
$ 9.6520 ft FORM WORK TOTAL COST
2.000.10red shot20
TOTAL
UNITAR
Y PRICE
DESCRIPTIONQ
COST OF FORMING ACCESSORIES PER LINEAL FOOT
$ 0.48Cost lineal foot of wall 8 feet height
$ 9.6520 ft FORM WORK TOTAL COST
2.000.10red shot20
TOTAL
UNITAR
Y PRICE
DESCRIPTIONQ
COST OF FORMING ACCESSORIES PER LINEAL FOOT
$ 1.26
Cost per lineal foot snap ties of wall 8
ft height
25.20Total cost of 20 ft wall
25.200.423m short 6" snapties60
TOTAL
UNITAR
Y PRICE
DESCRIPTIONQ
SNAP TIES FOR 6" WALL
$ 1.26
ft height
TOTAL
UNITAR
Y PRICE
DESCRIPTIONQ
ACCESSORIES
SNAP TIES
$ 3.00
ft height
TOTAL
UNITAR
Y PRICE
DESCRIPTIONQ
$ 3.00
ft height
TOTAL
UNITAR
Y PRICE
DESCRIPTIONQ
Snap ties holding the two panels of the formwork are per use. Cost to be added.

STUCCO COST
Dimensions correspond to
the floor plan on page 31.
The length of the wall
segment of each axis was
multiplied by the height,
which includes the wall and
the parapet. These segment
areas were added to obtain a
total (A). The flat fee
contracted for the case study
house, which included labor
and material, was divided by
the total square feet. The
cost gives the average cost
per square foot of stucco.
Note that the price for stucco
on a “standard” 8-foot high
wall would be $ 8.72 per
linear foot.
$ 1.09average cost per sf
$ 2,800.00flat fee labor and material negotiated:
2,572.4019510.019.5kitchen/familyD-F9
16010.016.0master bedroom west9-12F
22510.022.5master bedroom/bathF-J12
52510.052.53 bedrroms/master2-12J
22010.022.0bath/bedrrom 1F-J2
7010.07.0bath3-2F
3510.03.5living east3-3'C'
16010.016.0living northC-C'3
6010.06.0casita east1-3C
15510.015.5casita northB-C1
15010.015.0casita west1-4B
63.99.07.1garage east9-11D
2169.024.0garage southA-D11
49.59.05.5garage northA-B4
2889.032.0garage entry4-11A
total Aareaheightlengthdescriptionbetweenaxes
STUCCO AT FACADES -
$ 1.09average cost per sf
$ 2,800.00flat fee labor and material negotiated:
2,572.4019510.019.5kitchen/familyD-F9
16010.016.0master bedroom west9-12F
22510.022.5master bedroom/bathF-J12
52510.052.53 bedrroms/master2-12J
22010.022.0bath/bedrrom 1F-J2
7010.07.0bath3-2F
3510.03.5living east3-3'C'
16010.016.0living northC-C'3
6010.06.0casita east1-3C
15510.015.5casita northB-C1
15010.015.0casita west1-4B
63.99.07.1garage east9-11D
2169.024.0garage southA-D11
49.59.05.5garage northA-B4
2889.032.0garage entry4-11A
total Aareaheightlengthdescriptionbetweenaxes
STUCCO AT FACADES -

NAILERS
$ 1.32
Cost per lineal foot nailers to hold
gypsum board 16" wall 8 ft height
0.500.50lote nails to hold metal 1.5/81
2.600.26styrofoam backing 1n 1.5/8" studs10
23.202.321.5/8" 25ga stud 8'10
TOTAL
UNITAR
Y PRICE
DESCRIPTIONQ
NAILERS ON 16" WALL
$ 1.32
Cost per lineal foot nailers to hold
gypsum board 16" wall 8 ft height
23.202.321.5/8" 25ga stud 8'10
TOTAL
UNITAR
Y PRICE
DESCRIPTIONQ
NAILERS ON 16" WALL
$ 1.32
Cost per lineal foot gypsum nailers
one face of wall 8 ft height
23.202.321.5/8" 25ga stud 8'10
TOTAL
UNITAR
Y PRICE
DESCRIPTIONQ
GYP. BD. NAILERS FOR 6" WALL
$ 1.32
Cost per lineal foot gypsum nailers
one face of wall 8 ft height
23.202.321.5/8" 25ga stud 8'10
TOTAL
UNITAR
Y PRICE
DESCRIPTIONQ
GYP. BD. NAILERS FOR 6" WALL
Gypsum board (drywall) panels are
used to face the interior of the walls
because this is what consumers
expect. In order to have an effective
nailing surface (other than concrete) to
hold the gyp board, the CRH method
uses nailers of 1.5/8” metal studs with
a backing of Styrofoam set into the
formwork to be embedded in concrete
during pouring.
Patent Pending.
One nailer along the stem of each rib. Ribs are 24 in on center.
When the face of a wall 6 in thick will be
covered with drywall, nailers are used.
The cost analyzed is per linear foot of wall.

INSULATION
Work of hanging drywall on the walls was negotiated at a flat fee, including labor, materials,
taping and texturing. The table on age 56 contains detail used to establish cost of walls.
GYPSUM BOARD
CONCRETE
$ 0.58 SF
$ 22.85
Cost per lineal foot blocks of
insulation 16" wall 8 ft height
54.002.701.5x1.5 angle 25 ga 10'20
403.0040.30styrofoam 20x14x9610
TOTAL
UNITAR
Y PRICE
DESCRIPTIONQ
RIGID INSULATION 16" WALL
$ 22.85
Cost per lineal foot blocks of
insulation 16" wall 8 ft height
54.002.701.5x1.5 angle 25 ga 10'20
403.0040.30styrofoam 20x14x9610
TOTAL
UNITAR
Y PRICE
DESCRIPTIONQ
RIGID INSULATION 16" WALL
$ 14.28
Cost per LF concrete 6" wall 8 ft
height
285.5296.46Volume 0.5x8x20/27 in CY2.96
TOTAL
UNITAR
Y PRICE
DESCRIPTIONQ
CONCRETE IN 6" WALL
$ 14.28
height
285.5296.46Volume 0.5x8x20/27 in CY2.96
TOTAL
UNITAR
Y PRICE
DESCRIPTIONQ
CONCRETE IN 6" WALL
$ 5.47
height
14.2896.46volume 9 ribs= 0.33x1.55x8/27 in CY0.148
95.2196.46Volume diaphram 0.17x20x8/27 in CY0.987
TOTAL
UNITAR
Y PRICE
DESCRIPTIONQ
CONCRETE IN 16" WALL
$ 5.47
height
14.2896.46volume 9 ribs= 0.33x1.55x8/27 in CY0.148
95.2196.46Volume diaphram 0.17x20x8/27 in CY0.987
TOTAL
UNITAR
Y PRICE
DESCRIPTIONQ
CONCRETE IN 16" WALL

These costs include labor and
materials such as rebar, pencil
rods, wire mats, and wire ties
per structural calculations.
REINFORCEMENT
$ 5.95119.09reinforcement 16in wall
48.0016.00hours steel reinforcement3
3.593.5916 ga wire tie1
10.102.021/4 pencil rod 20'5
15.103.02#3 rebar 20 feet5
23.280.292x2 dobie w/wire80
19.0215.856x6 10x10 wire mats 7'x20'1.2
6"wall
8' height
$/ft
TOTAL
UNITARY
PRICE
DESCRIPTIONQ
STUDY COST OF WALL 16"x20'x8'steel reinforcement and labor
48.0016.00hours steel reinforcement3
3.593.5916 ga wire tie1
10.102.021/4 pencil rod 20'5
15.103.02#3 rebar 20 feet5
23.280.292x2 dobie w/wire80
19.0215.856x6 10x10 wire mats 7'x20'1.2
6"wall
8' height
$/ft
TOTAL
UNITARY
PRICE
DESCRIPTIONQ
32.0016.00hours steel reinforcement labor2
7.183.5916 ga wire tie2
4.042.021/4 pencil rod 20'2
96.643.02#3 rebar 20 feet32
6"wall
8' height
$/ft
TOTAL
UNITARY
PRICE
DESCRIPTIONQ
32.0016.00hours steel reinforcement labor2
7.183.5916 ga wire tie2
4.042.021/4 pencil rod 20'2
96.643.02#3 rebar 20 feet32
6"wall
8' height
$/ft
TOTAL
UNITARY
PRICE
DESCRIPTIONQ

PLACING FORMWORK
$ 4.7695.20formwork in place 16in wall
16.0016.00hours helper carpenter placing styrofoam1
35.2016.00hours helper carpenter2.2
44.0020.00hours carpenter, trace, align, plumb, brace2.2
6"wall
8' height
$/ft
TOTAL
UNITARY
PRICE
DESCRIPTIONQ
STUDY COST OF WALL 16"x20'x8'setting form work
16.0016.00hours helper carpenter placing styrofoam1
35.2016.00hours helper carpenter2.2
44.0020.00hours carpenter, trace, align, plumb, brace2.2
6"wall
8' height
$/ft
TOTAL
UNITARY
PRICE
DESCRIPTIONQ
Placing formwork for 6-
inch walls and 16-inch
walls are similar. 16in
walls have the rigid
insulation placed using
metal angles and
dobies in coordination
with the reinforcement
steel.
32.0016.00hours helper carpenter2
40.0020.00hours carpenter, trace, align, plumb, brace2
6"wall
8' height
$/ft
TOTAL
UNITARY
PRICE
DESCRIPTIONQ
32.0016.00hours helper carpenter2
40.0020.00hours carpenter, trace, align, plumb, brace2
6"wall
8' height
$/ft
TOTAL
UNITARY
PRICE
DESCRIPTIONQ

CONCRETE POURING
This phase of the
construction uses a
team of concrete
workers using a
concrete pump and
vibrator. The pump is
rented. The vibrator and
scaffolds are included in
the concrete sub-
contractor fee.
$ 11.30226.08pouring concrete 16in wall
190.7689.98CUY concrete pouring2.12
35.3216.66CUY concrete pumping2.12
$ F/8'htTOTAL
UNITARY
PRICE
DESCRIPTIONQ
STUDY COST OF WALL 16"x20'x8'concrete pouring by pump.
$ F/8'htTOTAL
UNITARY
PRICE
DESCRIPTIONQ
$ F/8'htTOTAL
UNITARY
PRICE
DESCRIPTIONQ
$ F/8'htTOTAL
UNITARY
PRICE
DESCRIPTIONQ

TOTAL CONSTRUCTION COST OF WALLS
Using the values obtained in the
cost studies in the page noted
from the table at right, the
different cost for each one of the
walls used in the CRH Case Study
will be shown on the following
pages.
11.30LF/8' ht105Concrete pouring 16in wall
4.76LF/8' ht104Placing formwork for 16in wall
5.96LF/8' ht103Steel reinforcement 16in wall
5.47LF/8' ht102Concrete 16in wall
22.85LF/8' ht102Insulation
0.80SF102Gypsum board
1.32LF/8' ht101Nailers 16in wall
1.09SF100Stucco
3.00LF/8' ht99Snap ties 16in wall
0.48LF/8' ht99Formwork accessories
1.40LF/8' ht98Formwork
$UNITpageDESCRIPTION
22.85LF/8' ht37Insulation
0..58SF37Gypsum board
1.09SF35Stucco
0.48LF/8' ht34Formwork accessories
1.40LF/8' ht33Formwork
$UNITpageDESCRIPTION

TYPE A – RIBBED WALL WITH INSULATION
69.79LF/8' ht
TOTAL 6"wall 8' height
6.400.80SFStucco8
8.721.09SFdrywall8
11.3011.30LF/8' htConcrete pouring 6 in wall1
5.475.47LF/8' htConcrete 6x12x96 inches1
6.996.99LF/8' htSteel reinforcement 6 in wall1
1.321.32LF/8' htNailers 6 in wall1
1.261.26LF/8' htSnap ties 6 in wall1
22.8522.85LF/8' htInsulation1
3.603.60LF/8' htPlacing formwork for 16 in wall1
0.480.48LF/8' htFormwork accessories1
1.401.40LF/8' htFormwork1
TOTAL
UNITAR
Y PRICE
UNITDESCRIPTIONQ
STUDY COST OF WALL 16" drywall/stucco
65.71LF/8' ht
6.400.80SFStucco8
4.640.58SFdrywall8
22.8522.85LF/8' htInsulation1
TOTAL
UNITAR
Y PRICE
UNITDESCRIPTIONQ

TYPE B – UNRIBBED WALL
UNRIBBED WALL TYPE B (see detail 2 on page 32)
There are different costs regarding the material used to
cover the faces.
51.51LF/8' ht
6.400.80SFStucco8
TOTAL
UNITAR
Y PRICE
UNITDESCRIPTIONQ
STUDY COST OF WALL 6" exposed/stucco
51.51LF/8' ht
6.400.80SFStucco8
TOTAL
UNITAR
Y PRICE
UNITDESCRIPTIONQ
STUDY COST OF WALL 6" exposed/stucco
60.23LF/8' ht
6.400.80SFStucco8
8.721.09SFdrywall8
TOTAL
UNITAR
Y PRICE
UNITDESCRIPTIONQ
56.15LF/8' ht
6.400.80SFStucco8
4.640.58SFdrywall8
TOTAL
UNITAR
Y PRICE
UNITDESCRIPTIONQ

TYPE B – UNRIBBED WALL
62.55LF/8' ht
17.441.09SFdrywall16
TOTAL
UNITAR
Y PRICE
UNITDESCRIPTIONQ
STUDY COST OF WALL 6" drywall/drywall
54.39LF/8' ht
9.280.58SFdrywall16
TOTAL
UNITAR
Y PRICE
UNITDESCRIPTIONQ
STUDY COST OF WALL 6" drywall/drywall
53.83LF/8' ht
8.721.09SFdrywall8
TOTAL
UNITAR
Y PRICE
UNITDESCRIPTIONQ
STUDY COST OF WALL 6" exposed/drywall
49.75LF/8' ht
4.640.58SFdrywall8
TOTAL
UNITAR
Y PRICE
UNITDESCRIPTIONQ
STUDY COST OF WALL 6" exposed/drywall

ROOF
..
The Microsoft Office Excel generated tables analyze labor and materials per square foot of roof of
the CRH structure in the study:
• Formwork and pipes used for shoring are rented. Beams and boards cost to be prorated by 40
uses, are in page 48.
• Labor and accessories for formwork on page 49.
• Labor for stems and flange reinforcement and placing block insulation on page 52.
• Rebar, mesh and metal nailers material on page 53.
• The rigid insulation blocks and mesh to reinforce the top slab (T-beam’s flange) on page 54.
• Fast set concrete used in roof to reduce the construction time on page 54.
• Drywall used in ceilings and walls are discussed on page 56.
• Roofing labor and materials on page 57.
The cost study uses direct costs of the elements used for the roof structure as shown in the list below.The cost study uses direct costs of the elements used for the roof structure as shown in the list below.
Refer to the plan and structural detailsRefer to the plan and structural details on pages 46 and 47.

ROOF PLAN SHOWING POSTS AND BEAMS FOR FORMWORK

ROOF STRUCTURAL DETAILS

$ 0.02Cost per SF of lumber per use to pour a roof
69.28Cost per use
2,771.34Total cost lumber for Case Study
1,302.0037.204x8x14 wood beams35
1,469.349.072x8x8 boards used162
TOTAL
UNITARY
PRICE
DESCRIPTIONQ
ROOF FORMWORK - wood beams and boards 40 uses
$ 0.02Cost per SF of lumber per use to pour a roof
69.28Cost per use
1,302.0037.204x8x14 wood beams35
1,469.349.072x8x8 boards used162
TOTAL
UNITARY
PRICE
DESCRIPTIONQ
ROOF FORMWORK - wood beams and boards 40 uses
The rental of shoring pipe is cost effective because
it includes the delivery and return to the renting
company. The pipes do not need to be stored or
maintained. Minimal investment is necessary. In
the case study 129 shoring pipes were used for the
roof of 2850 SF.
Cost is shown at the Table at left.
Beams and boards are
supported by the shoring pipe.
These serves to hold the
concrete in the ribs as well as
the rigid insulation between the
ribs. Beams and boards need
to be purchased. The cost
study assumes 40 uses of a set
of beams and boards,
averaging the cost, as shown
here.
$ 0.17Cost per SF pipe shore used
496.48Cost per 7 days rent
2,127.77Total cost 80 pipes a month
902.270.74tax of pipe shore per month
1,225.509.50pipe shore w/head rent per month129
TOTAL
UNITARY
PRICE
DESCRIPTIONQ
ROOF FORMWORK - pipe shore 10 days
use
$ 0.17Cost per SF pipe shore used
496.48Cost per 7 days rent
2,127.77Total cost 80 pipes a month
902.270.74tax of pipe shore per month
1,225.509.50pipe shore w/head rent per month129
TOTAL
UNITARY
PRICE
DESCRIPTIONQ
ROOF FORMWORK - pipe shore 10 days
use

$ 0.43Cost per SF labor and accesories to set formwork
1,242.35
Cost per 2,800 SF of roof at Case
Study
30.0030.00lote nails nails and red shot1
46.980.291.5/8" 25ga stud 8'162
1,152.0012.00hours used by 8 laborer in day and half96
TOTAL
UNITARY
PRICE
DESCRIPTIONQ
ROOF FORMWORK - labor and related materials
$ 0.43Cost per SF labor and accesories to set formwork
1,242.35
Cost per 2,800 SF of roof at Case
Study
30.0030.00lote nails nails and red shot1
46.980.291.5/8" 25ga stud 8'162
1,152.0012.00hours used by 8 laborer in day and half96
TOTAL
UNITARY
PRICE
DESCRIPTIONQ
ROOF FORMWORK - labor and related materials
Labor involves placing the shoring pipes
and putting the 4x8 wood beams on the
pipe heads to receive the 2x8 boards.
The boards are nailed to the beams, and
serve to brace the formwork, facilitating
the placing of nailers which will serve to
hold the drywall ceiling. These tasks are
simple and do not require special skills;
entry level construction laborers can do
this with no problem.
31184Total to be used by cost study w/15% add for splicing
27.18160.1Total
18.63T-beams both sides supported on 16" walls
68.11T-beams one side 6" wall other side 16" wall
27.1873.32T-beams supported on 6" walls
20FT rebar #4
TOTAL
20FT rebar #3
TOTALTotal per case study of beams noted
ROOF T-BEAMS STEEL REINFORCEMENT resume
31184Total to be used by cost study w/15% add for splicing
27.18160.1Total
18.63T-beams both sides supported on 16" walls
68.11T-beams one side 6" wall other side 16" wall
27.1873.32T-beams supported on 6" walls
20FT rebar #4
TOTAL
20FT rebar #3
TOTALTotal per case study of beams noted
ROOF T-BEAMS STEEL REINFORCEMENT resume
The table at the right shows the total
rebar numbers used to build the case
study following the structural
calculations reflected on pages 112 and
113. The following pages detail the
process of obtaining these totals.
Costs for additional components of the
roof will be shown in the following
pages.

27.1873.32rebars of 20 feet length
543.581,466.42rebars in LF
031.087.502.8636.507.5010A
12062.8524.0012.57523.0024.009A
116.25178.0523.2523.2512.36522.2523.258A
43.567.3621.7521.7511.93220.7521.756A
202.5318.9020.2520.2511.641019.7520.255A
40.5197.6420.2535.6827.46216.8317.834sim
20.8332.5020.8320.8311.67119.8320.834A
0153.6833.1610.52215.8316.583A
0288.5631.0010.14414.5015.502A
0135.8029.009.90213.6614.501A
#4
TOTAL
#3
TOTAL
positive
reinf.
1#4
positive
reinf.
2#3
positive
reinf.
1#3
pinned
support
#3
negative
reinf.
bea
ms
Qspan LF
beam
length
includin
g wall
support
s LFtype
ROOF T-BEAMS STEEL REINFORCEMENT supported on 6" walls
27.1873.32rebars of 20 feet length
543.581,466.42rebars in LF
031.087.502.8636.507.5010A
12062.8524.0012.57523.0024.009A
116.25178.0523.2523.2512.36522.2523.258A
43.567.3621.7521.7511.93220.7521.756A
202.5318.9020.2520.2511.641019.7520.255A
40.5197.6420.2535.6827.46216.8317.834sim
20.8332.5020.8320.8311.67119.8320.834A
0153.6833.1610.52215.8316.583A
0288.5631.0010.14414.5015.502A
0135.8029.009.90213.6614.501A
#4
TOTAL
#3
TOTAL
positive
reinf.
1#4
positive
reinf.
2#3
positive
reinf.
1#3
pinned
support
#3
negative
reinf.
bea
ms
Qspan LF
beam
length
includin
g wall
support
s LFtype
ROOF T-BEAMS STEEL REINFORCEMENT supported on 6" walls
68.11rebars of 20 feet length
1,362.17rebars in LF
387.5235.6812.76820.0021.006B
61.5012.30519.0020.004
464.9033.1613.331015.8316.833
174.0031.0012.50413.7514.752
274.2529.0013.7512.10512.7513.751
#3
TOTAL
positive
reinf. 2#3
positive
reinf. 1#3
pinned
support
#3
negative
reinf.
beams
Qspan LF
beam
length
includin
g wall
supports
LFtype
ROOF T-BEAMS one on 6" the other 16" walls.
1,362.17rebars in LF
387.5235.6812.76820.0021.006B
61.5012.30519.0020.004
464.9033.1613.331015.8316.833
174.0031.0012.50413.7514.752
274.2529.0013.7512.10512.7513.751
#3
TOTAL
positive
reinf. 2#3
positive
reinf. 1#3
pinned
support
#3
negative
reinf.
beams
Qspan LF
beam
length
includin
g wall
supports
LFtype
ROOF T-BEAMS one on 6" the other 16" walls.
Different design conditions make the supporting
walls of the roof different. At left we have the
study of a roof supported on 6” walls at both
ends.
The table at right shows the roof T-beams to
be supported by a 6” wall in one side and a
16” wall on the opposite side.

372.60rebars in LF
76.2045.0031.20121.5022.508
296.4043.5030.60420.7521.757
#3
TOTAL
positive
reinf.
2#3
positiv
e reinf.
1#3
pinned
support
#3
negative
reinf.
beams
Qspan LF
beam
length
includin
g wall
support
s LFtype
ROOF T-BEAMS both supports on 16" walls.
372.60rebars in LF
76.2045.0031.20121.5022.508
296.4043.5030.60420.7521.757
#3
TOTAL
positive
reinf.
2#3
positiv
e reinf.
1#3
pinned
support
#3
negative
reinf.
beams
Qspan LF
beam
length
includin
g wall
support
s LFtype
ROOF T-BEAMS both supports on 16" walls.
84.253,261.482,717.90
1.4054.0045.00122.508
5.39208.80174.00421.757
10.42403.20336.00821.006B
6.20240.00200.00520.004
10.43403.92336.601016.833
3.66141.60118.00414.752
4.26165.00137.50513.751
1.4054.0045.0037.5010A
7.44288.00240.00524.009A
7.21279.00232.50523.258A
2.70104.4087.00221.756A
12.56486.00405.001020.255A
2.2185.5871.32217.834sim
1.2949.9941.66120.834A
2.0679.5866.32216.583A
3.84148.80124.00415.502A
1.8069.6058.00214.501A
CY
concret
e at
flanges,
stems
factor
0.062
SF of
wire
mesh in
flange
SF of
wire
mesh as
stirrups
beams
Q
beam
length
includin
g wall
support
s LFtype
ROOF: mesh 6x6-w2.5xw2.5-concrete
84.253,261.482,717.90
1.4054.0045.00122.508
5.39208.80174.00421.757
10.42403.20336.00821.006B
6.20240.00200.00520.004
10.43403.92336.601016.833
3.66141.60118.00414.752
4.26165.00137.50513.751
1.4054.0045.0037.5010A
7.44288.00240.00524.009A
7.21279.00232.50523.258A
2.70104.4087.00221.756A
12.56486.00405.001020.255A
2.2185.5871.32217.834sim
1.2949.9941.66120.834A
2.0679.5866.32216.583A
3.84148.80124.00415.502A
1.8069.6058.00214.501A
CY
concret
e at
flanges,
stems
factor
0.062
SF of
wire
mesh in
flange
SF of
wire
mesh as
stirrups
beams
Q
beam
length
includin
g wall
support
s LFtype
ROOF: mesh 6x6-w2.5xw2.5-concrete
The tables on page 50 and 51refered to T-beam types
are as structural details in page 47, as well mesh
reinforcement.
Note than the structural documents use the word joist
for the T-beams.
The table at right shows the welded wire mesh 6x6 –
w2.5xw2.5 used for beam stem as stirrups and steel
reinforcement of the beam flange.
The table also shows the amount of concrete in cubic
yards used to build the roof of the Case Study Concrete
Rib House,

$ 0.56Cost per lineal foot
13.50Total cost of 24 FT rib and insulation
6.0012.00
half hour 1 laborer set insulation for 24
FT beam0.5
1.5012.00
quarter hour 1 laborer set
reinforcement on place a 24 FT beam0.25
6.0012.00
half hour 1 laborer prepare material
and assemble reinforcement for 24 FT
beam0.5
TOTAL
UNITARY
PRICE
DESCRIPTIONQ
STEEL REINFORCEMENT and placing insulation
$ 0.56Cost per lineal foot
13.50Total cost of 24 FT rib and insulation
6.0012.00
half hour 1 laborer set insulation for 24
FT beam0.5
1.5012.00
quarter hour 1 laborer set
reinforcement on place a 24 FT beam0.25
6.0012.00
half hour 1 laborer prepare material
and assemble reinforcement for 24 FT
beam0.5
TOTAL
UNITARY
PRICE
DESCRIPTIONQ
STEEL REINFORCEMENT and placing insulation
$ 0.05
Cost per square foot deducting
overlaping
6.0012.00
half hour 1 laborer place a math of
7x20 FT on roof with 2x2 dobies0.5
TOTAL
UNITARY
PRICE
DESCRIPTIONQ
REINFORCEMENT placing wire mesh
$ 0.05
Cost per square foot deducting
overlaping
6.0012.00
half hour 1 laborer place a math of
7x20 FT on roof with 2x2 dobies0.5
TOTAL
UNITARY
PRICE
DESCRIPTIONQ
REINFORCEMENT placing wire mesh
The table at left shows time used
to cut and assemble rebar, wire
mesh, stirrups and pencil rod.
Another laborer places the
reinforcement in the formwork after
setting the nailers in place, and
another worker places the block
insulation and puts wires and 2x2
metal angles to hold the blocks in
place. The times are averages
obtained by observation of 3
laborers during 8 hours work.
Once the reinforcement of the ribs
(stems) and insulation, is in place,
a worker lays wire mesh on top
overlapping 12 inches and tying the
mesh with wire; special 2x2-inch
dobies are used to keep the mesh
reinforcement centered in the two
inches slab thickness.
The time was averaged by
observation of crew doing the job.

161.47
2x4x8 boards & 8'
nailersrequired
1,291.77
21.50121.508
83.00420.757
160.00820.006B
95.00519.004
158.301015.833
55.00413.752
63.75512.751
19.5036.5010A
115.00523.009A
111.25522.258A
41.50220.756A
197.501019.755A
33.66216.834sim
19.83119.834A
31.66215.833A
58.00414.502A
27.32213.661A
Total
length
bottom
ribs LF
beams
QLF spantype
ROOF T-beam bottom stems
161.47
2x4x8 boards & 8'
nailersrequired
1,291.77
21.50121.508
83.00420.757
160.00820.006B
95.00519.004
158.301015.833
55.00413.752
63.75512.751
19.5036.5010A
115.00523.009A
111.25522.258A
41.50220.756A
197.501019.755A
33.66216.834sim
19.83119.834A
31.66215.833A
58.00414.502A
27.32213.661A
Total
length
bottom
ribs LF
beams
QLF spantype
ROOF T-beam bottom stems
The table above shows cost calculations of steel reinforcement for ribs
(stem) of the T-beams including the nailers which are set by the laborers
during the same phase of placing the stem reinforcement.
The table at right shows calculations for bottom of ribs.
Table on next page calculations of total length of ribs – refer to floor plan
in page 46 for information.
$ 0.50Cost per SF roof T-beams stem
$ 1,432.17Total cost of T-beam stem in 2080 SF roof
10.773.5916 ga wire tie - roll3
40.402.02pencil rod 20' - pg 10320
417.962.581.3/8" stud 8' and styrofoam backing - pg 101162
317.0015.85wire mesh 6x6 w2.5xw2.5 - 20'x7' - pg 103*20
57.383.02Rebar #3 T-beams on 16"-16" walls - pg 11619
156.805.60Rebar #4 in T-beams on 6" walls - pg 11528
TOTAL
UNITARY
PRICE
DESCRIPTIONQ
ROOF T-BEAMS Rib (stem) reinforcement and nailer
$ 0.50Cost per SF roof T-beams stem
$ 1,432.17Total cost of T-beam stem in 2080 SF roof
10.773.5916 ga wire tie - roll3
40.402.02pencil rod 20' - pg 10320
417.962.581.3/8" stud 8' and styrofoam backing - pg 101162
317.0015.85wire mesh 6x6 w2.5xw2.5 - 20'x7' - pg 103*20
TOTAL
UNITARY
PRICE
DESCRIPTIONQ
ROOF T-BEAMS Rib (stem) reinforcement and nailer

1,358.95
22.50122.508
87.00421.757
168.00821.006B
100.00520.004
168.301016.833
59.00414.752
68.75513.751
22.5037.5010A
120.00524.009A
116.25523.258A
43.50221.756A
202.501020.255A
35.66217.834sim
20.83120.834A
33.16216.583A
62.00415.502A
29.00214.501A
Total
length
reinf.
beams
Q
beam
length
including
wall
supports
LFtype
T-BEAMS total by LF
1,358.95
22.50122.508
87.00421.757
168.00821.006B
100.00520.004
168.301016.833
59.00414.752
68.75513.751
22.5037.5010A
120.00524.009A
116.25523.258A
43.50221.756A
202.501020.255A
35.66217.834sim
20.83120.834A
33.16216.583A
62.00415.502A
29.00214.501A
Total
length
reinf.
beams
Q
beam
length
including
wall
supports
LFtype
T-BEAMS total by LF
The T-beam flange once poured becomes the top of the roof as a
continuous slab. The T-beams have supports at the heights which
can provide slopes of a minimum of ¼” per foot. Crickets can be
built to direct water on a flat roof toward the gargoyles.
Parapet walls and concrete beams will be the complement of the roof
structure, being studied as a separate section.
$ 5.04Cost per SF roof insulation
40.3040.30styrofoam 20x14x961
TOTAL
UNITARY
PRICE
DESCRIPTIONQ
ROOF T-BEAMS rigid insulation
$ 5.04Cost per SF roof insulation
40.3040.30styrofoam 20x14x961
TOTAL
UNITARY
PRICE
DESCRIPTIONQ
ROOF T-BEAMS rigid insulation
$ 0.96Cost per SF roof concrete flange
$ 2,746.56
Total cost of T-beam flange in 2080 SF
roof
37.700.292x2 dobies w/wire - pg 103130
14.363.5916 ga wire tie - roll - pg 1034
2,694.5015.85wire mesh 6x6 w2.5xw2.5 - 20'x7' - pg 116170
TOTAL
UNITARY
PRICE
DESCRIPTIONQ
ROOF T-BEAMS flange reinforcement
$ 0.96Cost per SF roof concrete flange
$ 2,746.56
Total cost of T-beam flange in 2080 SF
roof
37.700.292x2 dobies w/wire - pg 103130
14.363.5916 ga wire tie - roll - pg 1034
2,694.5015.85wire mesh 6x6 w2.5xw2.5 - 20'x7' - pg 116170
TOTAL
UNITARY
PRICE
DESCRIPTIONQ
ROOF T-BEAMS flange reinforcement

Construction speed is
important to minimize
cost of construction
loans. The CRH, as a
system to produce
buildings in large
numbers, uses fast set
concrete to reduce the
setting time of concrete
from the standard 28
days to only 3 days.
Using fast set concrete,
the formwork for the roof
is soon moved to the
next building, allowing
the next phase of
construction to continue.
For competitive quality
and price the concrete
used to build the roof
had fiber glass mesh in
the mix.
The cost was recorded
from pouring of 40 CY
during the construction of
the case study CRH.
$ 5.09Cost per SF concrete
$ 174.04Cost per lineal CY concrete at roof
6,961.63Total cost of 40 CY at roof
60.0020.00days 2 hours water curing3
1,170.001,170.0040 CY labor for roof concrete pouring1
398.009.95pumping first 9 $150 - next $8 each40
21.700.54tax0.0775
280.007.00CY fiber mesh (blue box)40
361.939.05tax to concrete0.0775
4,670.00116.75CY 8.5 sack & M.R. 3/8"40
TOTAL
UNITARY
PRICE
DESCRIPTIONQ
FAST SET CONCRETE
$ 5.09Cost per SF concrete
$ 174.04Cost per lineal CY concrete at roof
6,961.63Total cost of 40 CY at roof
60.0020.00days 2 hours water curing3
1,170.001,170.0040 CY labor for roof concrete pouring1
398.009.95pumping first 9 $150 - next $8 each40
21.700.54tax0.0775
280.007.00CY fiber mesh (blue box)40
361.939.05tax to concrete0.0775
4,670.00116.75CY 8.5 sack & M.R. 3/8"40
TOTAL
UNITARY
PRICE
DESCRIPTIONQ
FAST SET CONCRETE

This page shows the detail of the walls and ceiling faced with
drywall. The difference in cost between wall and ceiling were
obtained by observation of the process.

$ 3.01Cost per SF roofing
8,650.008,650.00
2780 SF roof covered area, flat fee
including 3" cant strip, metal cap,
skylight bases sealed. Labor and
materials1
TOTAL
UNITARY
PRICE
DESCRIPTIONQ
ROOFING - flat roof cold application fiber glass base #75
$ 3.01Cost per SF roofing
8,650.008,650.00
2780 SF roof covered area, flat fee
including 3" cant strip, metal cap,
skylight bases sealed. Labor and
materials1
TOTAL
UNITARY
PRICE
DESCRIPTIONQ
ROOFING - flat roof cold application fiber glass base #75The roof waterproofing job was a flat cost
negotiated for a high quality including the
parapet walls, the skylights bases, cold to
primer roof holding single fiberglass base
#75. Torch down polyglass modified, corners
sealed with roof cement and granules.
ROOF CRH DIRECT COST $ 16.70 / SFROOF CRH DIRECT COST $ 16.70 / SF
16.70Direct Cost of Roof CRH method per SF .
1223.01SFLabor and material - roofing
1210.87SFLabor and material - drywall on ceiling
1205.09SFFast set concrete: material, labor setting, pumping
1190.96SFMaterial reinforcement for T - beam flange (slab cover)
1195.04SFRigid insulation blocks
1180.50SFMaterial reinforcement for T -beam stem includes nailers.
1170.05SFlabor reinforcement flange T -beam Rib (stem)
1170.56SFLabor stems reinforcement and placing insulation
1140.43SFCost per SF labor and accessories to set formwork
1130.02SFBeams and boards roof formwork (40 uses)
1130.17SFCost per rental pipe shore
See
PAGE
$UNITDESCRIPTION
16.70Direct Cost of Roof CRH method per SF .
573.01SFLabor and material - roofing
560.87SFLabor and material - drywall on ceiling
555.09SFFast set concrete: material, labor setting, pumping
540.96SFMaterial reinforcement for T - beam flange (slab cover)
545.04SFRigid insulation blocks
530.50SFMaterial reinforcement for T -beam stem includes nailers.
520.05SFlabor reinforcement flange T -beam Rib (stem)
520.56SFLabor stems reinforcement and placing insulation
490.43SFCost per SF labor and to set formwork
480.02SFBeams and boards roof formwork (40 uses)
480.17SFCost per rental pipe shore
See
PAGE
$UNITDESCRIPTION

BEARING & PARAPET BEAMS
Bearing beams are shown on page 59 as types A, B1, B2, C, and D.
Details of section dimensions and reinforcement are on page 60. Bill of materials and labor is shown in the
tables on the same page.
Beams forming part of the parapet walls are shown in the plan on page 61. Spans of parapet walls that receive a
load greater than the acceptable by the standard section and reinforcement are also detailed on page 61. Price
established on page 62.
A summary of bearing and parapet beams is on page 62, table at lower right.

BEARING BEAMS PLAN AND DETAILS

$ 2.46Cost per LF beam reinforcement
1.2012.00labor assembling0.1
0.363.5916 ga wire tie - roll - pg 1030.1
0.150.15#3 rebar LF stirrup1
0.760.15#3 rebar LF reinforcement5
TOTAL
UNITARY
PRICE
DESCRIPTIONQ
BEARING BEAMS - reinforcement
$ 2.46Cost per LF beam reinforcement
0.150.15#3 rebar LF stirrup1
TOTAL
UNITARY
PRICE
DESCRIPTIONQ
BEARING BEAMS - reinforcement
The cost study was calculated using reinforcement per
LF and a layer of concrete one inch deep by 6” wide x
one LF.
With the above criteria the cost of each beam type
required by structural calculations is shown in the table
at right.
$ 0.27Cost inch layer by one LF by 6"
0.267516.45
inch layer by one LF by 6" concrete 8.5
sack, pumped, pouring, and tax0.0415
TOTAL
UNITARY
PRICE
DESCRIPTIONQ
BEARING BEAMS - concrete
$ 0.27Cost inch layer by one LF by 6"
0.267516.45
inch layer by one LF by 6" concrete 8.5
sack, pumped, pouring, and tax0.0415
TOTAL
UNITARY
PRICE
DESCRIPTIONQ
BEARING BEAMS - concrete
$ 36.27Cost beam C 6X32X36
28.899.63Type D- 6"x36" - concrete3.00
7.382.46Type D - 6"x36" - reinforcement3.00
34.248.56Type C- 6"x32" - concrete4.00
9.842.46Type C - 6"x32" - reinforcement4.00
$ 52.86Cost beam B1 or B2 - 6x46x43
44.0512.31Type B1 or B2 - 6"x46" - concrete3.58
8.812.46Type B1 or B2 - 6"x46" - reinforcement3.58
$ 95.97Cost beam A - 6x46x78
79.9812.31Type A - 6"x46" - concrete6.5
15.992.46Type A - 6"x46" - reinforcement6.5
TOTAL
UNITARY
PRICE
DESCRIPTIONQ
BEARING BEAMS - reinforcement & concrete per type
28.899.63Type D- 6"x36" - concrete3.00
7.382.46Type D - 6"x36" - reinforcement3.00
34.248.56Type C- 6"x32" - concrete4.00
9.842.46Type C - 6"x32" - reinforcement4.00
$ 52.86Cost beam B1 or B2 - 6x46x43
44.0512.31Type B1 or B2 - 6"x46" - concrete3.58
8.812.46Type B1 or B2 - 6"x46" - reinforcement3.58
$ 95.97Cost beam A - 6x46x78
79.9812.31Type A - 6"x46" - concrete6.5
15.992.46Type A - 6"x46" - reinforcement6.5
TOTAL
UNITARY
PRICE
DESCRIPTIONQ
BEARING BEAMS - reinforcement & concrete per type

PARAPET BEAMS PLAN AND DETAILS

BEARING AND PARAPET BEAMS PER LFBEARING AND PARAPET BEAMS PER LF
$ 14.58Cost per LF beam E or E1
11.7711.77LF concrete 6x44 - material and labor1
0.340.11SF wire mesh 6x6 w2.5xw2.5 - 20'x7' - pg 1163
TOTAL
UNITARY
PRICE
DESCRIPTIONQ
PARAPET BEAMS TYPE E, E1- per LF
$ 14.58Cost per LF beam E or E1
0.340.11SF wire mesh 6x6 w2.5xw2.5 - 20'x7' - pg 1163
TOTAL
UNITARY
PRICE
DESCRIPTIONQ
PARAPET BEAMS TYPE E, E1- per LF
$ 9.54Cost per LF beam as the title
0.260.11SF wire mesh 6x6 w2.5xw2.5 - 20'x7' - pg 1162.33
TOTAL
UNITARY
PRICE
DESCRIPTIONQ
PARAPET BEAMS TYPE F to F4, G, H, J, K to K2, L & M - per LF
$ 9.54Cost per LF beam as the title
0.260.11SF wire mesh 6x6 w2.5xw2.5 - 20'x7' - pg 1162.33
TOTAL
UNITARY
PRICE
DESCRIPTIONQ
PARAPET BEAMS TYPE F to F4, G, H, J, K to K2, L & M - per LF
Above studies of parapet beams
as shown in floor plan and details
in page 126. The differences in
reinforcement and dimensions
were per loading conditions. For
example, parapet Beams E and
E1 are supporting the garage roof
at the span of garage doors.
1279.54LFCost per parapet beam F to F4, G, H, J, K to K2, L & M
12714.58LFCost per parapet beam E
12536.27PcCost per beam type D material & labor
12544.08PcCost per beam type C material & labor
12552.86PcCost per beam type B1, B2 material & labor
12595.97PcCost per beam type A material & labor
See
PAGE
$UNITDESCRIPTION
629.54LFCost per parapet beam F to F4, G, H, J, K to K2, L & M
6214.58LFCost per parapet beam E
6036.27PcCost per beam type D material & labor
6044.08PcCost per beam type C material & labor
6052.86PcCost per beam type B1, B2 material & labor
6095.97PcCost per beam type A material & labor
See
PAGE
$UNITDESCRIPTION

Using the information from pages 90 to 127 a cost of the Case Study shell is shown below. Remember this cost is
an average assuming construction of 40 units. More or fewer units will affect the results; generally the cost will be
lower if more than 40 units are built, and will be greater when fewer than 40 units are built.
The cost is DIRECT COST with no contractor’s mark up, workers compensation, overhead, taxes, or whatever can
be added for the working conditions, location, weather, etc.
COST OF SHELL of the Case Study CRH
Phase Q Unit DESCRIPTION
UNITARY
PRICE
Page TOTAL
FOUNDATION 2,870.00 SF Average cost 3.68 29 10,561.60
WALLS 131.00 LF Type A - 16" drywall/stucco 65.71 42 8,608.01
42.50 LF Type B - 6" exposed/stucco 51.51 43 2,189.18
24.00 LF Type B - 6" exposed/drywall 49.75 44 1,194.00
6.00 LF Type B - 6" stucco/drywall 56.15 43 336.90
55.00 LF Type B - 6" drywall/drywall 54.39 44 2,991.45
ROOF 2,870.00 SF Concrete, insulation, roofing and drywall 16.70 57 47,929.00
BEAMS 1.00 piece Type A - 6"x46" 95.97 60 95.97
1.00 piece Type B1 - 6"x46" 52.86 60 52.86
1.00 piece Type B1 - 6"x46" 52.86 60 52.86
1.00 piece Type C - 6"x32" 44.08 60 44.08
3.00 piece Type D - 6"x36" 36.27 60 108.81
32.50 LF Type E, E1 - parapet 6"x32" 14.58 62 473.85
250.50 LF Type F to M = parapet 6"x26" 9.54 62 2,389.77
Probable cost of the shell of the Case Study CRH if 40 units are build 77,028.34$
The Direct Cost of a CRH shell per Square Foot 19.90$
To work in a budget use the square foot cost of the sell by the build area and add the elements as windows,
plumbing, electrical, finishing, etc. also add contractor mark up and building permit, and play with such numbers to
reach the desired budget amount.

SAMPLES BASED
ON THE CASE STUDY
The following pages illustrate how using the set of forms from one house, Model 1, it is possible to reuse the
set in different configurations to produce many different designs, Models 2, 3, to Model x.
This flexibility is a plus for developers.

FLOOR PLAN OF THE CASE STUDY HOUSE

FLOOR PLAN MODIFIED # 1
3 car garage, laundry, mechanical, foyer, 3
bedrooms, bath, master bedroom, master bath,
walk-in closet, kitchen, dining, living, and terrace.

MAIN ENTRY DETAIL
From floor plan modified # 1

FROM FLOOR PLAN MODIFIED #1
Entry, foyer, living, dining, kitchen terrace.

BREAKFAST COUNTER, DINING
Floor plan modified # 1.

FLOOR PLAN MODIFIED #1
Terrace , note the corner window and the receded
windows and doors. Also the precast sill and
headers, features for the CRH innovative
construction system.

FROM FLOOR PLAN MODIFIED #1
Master bedroom, master bath, walk-in closet, the thickness of the exterior walls result of the rigid insulation
embedded: characteristic of the Concrete Rib House Construction System.

FLOOR PLAN MODIFIED #1
Bathroom detail

FLOOR PLAN MODIFIED # 2
Shows the living area similar to the Modified 1, but with 2 car
garage and the main entry facing the street, details of Modified
1 applied to this, plus the three following sketches.

Kitchen detail at modified 1 and 2, showing the pantry area and the serving the breakfast counter.

Kitchen detail view #2 at modified 1 and 2, showing the pantry area and the serving the breakfast counter.

Laundry room detail at modified 1 and 2, also shows the tub at bath and the guest closet at Foyer.

MODIFIED 3.
4 bedrooms, 2 car, with
loggia facing the street
the living area is similar
as Modified 1 and 2.
Details of living area
applied to all of them.

OPTION 4 – 3 bedrooms 2 car garage
Dimensions similar at the previous shown, only one
bedroom less and garage shorter by three feet, has a
nice loggia facing the street.

FLEXIBILITY
The reuse of formwork, generally up to 40 uses for plywood, can change the arrangement of the spaces providing many different models of
houses to give many options to buyers.
The design is not limited to one story. The reuse of the formwork can be applied to two or more stories.
Formwork can be done to create any texture or detail as moldings, trims or any gingerbread as desired or required by architectural style or
innovation in design, fiberglass or similar materials can achieve the negative shape to mold the concrete. This process can produce
very elaborated forms by the time of pouring the concrete with not expensive labor involved.
Design by modules can make the reuse of the formwork with out having to build 40 units to make effective the system.

FLOOD HAZARD AREAS
The floating mezzanine solution
This design, for people living in flood hazard zones,
enables them to stay safely in their homes, retaining
belongings, pets, etc., and avoiding the need to be
evacuated. The key is a floating upper floor, with all
the basics for living, including drinking water from a
built-in reservoir collecting rain water with a purifier
device, will be provided to survive the days of isolation.
Note: water lines contamination is probable under
flooding conditions.

A water reservoir is the core providing service to the fixtures
directly by straight connections in the first floor and
collapsible connections to the floating area. In normal
conditions services are provided by the local utilities. In
emergency conditions water can be obtained by rain, and
purified for drinking, bathing and cooking
Foundation built by
conventional methods.
Tank reinforced concrete
poured in place.

The ground level has laundry room, guest closet, powder room, full
kitchen with breakfast counter, and spacious area for living dining and
family activities. The sketch is shown with partial walls for clarity.

This image shows the core reservoir and the mezzanine with
exterior walls before installing the drywall to show the rigid
insulation embedded in concrete.
Walls in the first level omitted.

This sketch shows the 3 basic elements: foundation, reservoir tank
and the floating mezzanine.

Here the mezzanine is shown floating per Archimedes principle.
The volume of the rigid foam is calculated to carry the loads of
the mezzanine deck.

Ground level showing the foyer with the stairs and at
rear the 2 car garage. The beams on columns support
the mezzanine, which remains in place by gravity.

Detail of the powder room with access to the laundry room, no doors shown for
clarity, no drywall in place to show the rigid insulation in the walls.

This image shows the full kitchen in the ground floor. Note all fixtures requiring water are against the reservoir tank
wall, this saving on plumbing tubing costs.

Foyer detail showing stairs

Mezzanine floor plan showing the
emergency kitchen. The wall
nearest the reservoir is framed to
allow space for free movement of
the collapsible hoses when flooding
occurs. This keeps the water
running in the faucets of the
fixtures with no interruption.
Roofs of the garage and foyer
shown. Drywall panels are not
shown to give idea of how exterior
walls are insulated.
Master bedroom plus two
standard bedrooms shown.

Emergency food storage is contained
in the refrigerator attached to the wall of the floating
Mezzanine by a mechanism which allows movement
to be reach under flooding conditions.

Detail of bathroom on mezzanine, note the
separation between framed wall and concrete
tank wall of the reservoir. This allows movement
of the hoses connecting to the water supply
during flooding conditions.

The illustration at right shows the construction of the
mezzanine deck, using metallic trusses holding rigid foam
blocks and supporting the flooring plus the partition walls,
furniture and live loads.
The volume of the foam is calculated to float with all the
loads in the flooding. The corners of the mezzanine have
rolling devices to allow the vertical movement.
At left a detail of one connection by collapsible
hoses in between the reservoir tank and a
faucet, the collapsible hose lets free vertical
movement keeping the service uninterrupted.
Water in normal conditions services are provided
by the local utilities. In emergency conditions
water can be obtained by rain, and purified for
drinking, bathing and cooking.

.
The use of solar panels is another
feature to allow the people in the
house to have power for the light and
kitchen fixtures in emergency
situations.

Street view of the proposal for a Concrete Rib House with floating mezzanine.
Using this design concept can produce infinite solutions, even one story houses
with the flooring on a structure like the mezzanine shown on page 94.

LIVE and WORK
The dependence on oil has created the need to seek other sources of
energy. Meanwhile it is wiser to reduce our use of petroleum products
such as gasoline. Driving to work is eliminated when all you have to do
is go downstairs to be at the work place. Live and Work condo units
can be easily produced because the CRH system is ideal for the mass
production required by such developments.
Photovoltaic elements will serve besides to “fill the tank” of the automobiles
likely to be soon in available in the market for owning one.

The units are similar the differences are only in the walls types 6 in thick walls shared by two contiguous units. In the
rendered ground floor shows an end unit, the shared wall is labeled, as well the use of the areas/
This sample shows a possible musical store
6 in common wall
Garage,
storing and
laundry
Stairs to mezzanine
2 double doors
entries to the store
Store front windows

Detail corner showing one entry double door, the cahier station, merchandise for sale, the top of the stair.
The interior face of the walls are ready to be gyp board walled, except one in the garage/store area to show
the appearance after dry wall applied – the CRH system looks like the traditional framed walls -
Top of door to the powder room for
clients convenience.

This is an areal view of the ground floor with the concrete slab mezzanine in place and shows the stair in its stairs well

For clarity first the rendering shows the two bedrooms, the two closets and the bathroom with doors to each bedroom
also the stair going to the roof garden is shown
At right a detail of the shared bathroom of the
bedrooms with the door of bedroom one
shown., some walls removed for clarity.

At right detail of the living room, the
kitchen area with hard floor for the
service work, also in the bottom right
of the sketch partial of dining area in
the foreground the stair going to the
roof garden are shown.
The low walls and windows to
complete the façade are shown with
no drywall board applied to show the
encased rigid insulation characteristic
of the CRH system.
This two views are showing the dining area, the one at left has the door of bedroom one and the start of the stair,
the view at right shows the guardrail wall facing the store area. The opening of the living and dining areas to the
store makes convenient for the store owner to rest pleasantly when are not costumers in the store.

At left an overview of the slanting roof covered with
solar panels to provide for electric power for the
condo needs and to “fill the tank” of the future
electric car. Also the green area for landscaping
or growing vegetables to have a fresh salad when
wished.
A concrete build in spa to enjoy the sky view in a
relaxing worm water. A terrace area to have table
and sitting to have snacks and a cup of coffee.
At left a detail of the comfort area terrace and spa, the door to
the stairs well is shown at right of the picture

Some additions such as stair lifts, grab bars
and wider doors, can be used to
accommodate handicapped persons to occupy
Live and Work units.

Some shots of the vending area to convey information how an unit can display for business, which can be any use: ice
cream stores, artist galleries, bicycle shop, beauty saloon, law or dentist, real estate or any other office. You name what
you need is. Live up, work down and relax at the top….

Potpourri of samples
The design freedom of the CRH system is illustrated on the
following pages. Architectural styles using arches, protruding
elements such as moldings, brick walls, half timbered, gable
roofs, mansard style, frieze, architrave, or other decorative
elements --you name them. All can be incorporated at
reasonable cost simultaneously with the pouring of concrete
because decorative elements are in the formwork preparation.

A two story dwelling of a modified
Moroccan style. The protruding
decorative elements are produced
thanks to special accessories added to
the forms.
This house was built in Cancun where
hurricanes are frequent and strong
.
The house shown at the right was
built in the City of Mexico, where
earthquakes are the main concern.
There were 100 units built with 2 sets
of forms. At left a detail of the
balcony.
The project included two other
architectural styles for a total of 300
units as shown on the next page.

In the same development of the house on the
previous page, another 100 units built using 2 sets
of forms at a pace of 2 daily.
In Mexico the French style is highly appreciated.
Eugenio Aburto was able to provide it, even though
these houses were meant for an affordable market.
By using the accessories in the forms the moldings,
the shutters, and the mansard roofing were all
created at the time of pouring. This gave the homes
the desired character and made them a good buy.
Below is a detail of the balcony; the spindles are
precast elements using a light weight concrete..

This is a romantic Spanish style, reminiscent of the balcony on the first floor where the Spanish used to flirt with
the young lady living in the house. The sales of this style were terrific.

The poured-in-place concrete system developed by me
has no limitations. Here a multistory building is shown:
the Hotel Komvaser built in Cancun. The space under the
left wing of rooms is a big cistern to serve the water needs
for operation uninterrupted at any time. Hurricanes
sometimes shut down the Cancun water lines, but with
the cistern there was no water shortage.
The picture at right shows a vaulted roof built with a
combination of steel trusses and colored waterproof
plaster.
Note the use of arches and columns capitals, all done by
the special forming design.

As previously stated, the use of specially designed
forms is the way of obtaining complicated architectural
elements with poured concrete.
One of the many properties of concrete is taking the
shape of the mold. For repetitive shapes, the way to
build at low cost is by inserting liners or decorative
elements in the forms. The vaulted cantilevered roof
shown in the picture below was built using one
fiberglass form for all the roof. An embossed pattern
made the underside of the vault look like the traditional
Spanish terracotta blocks called “ladrillos.” A final coat
of color made the appearance real. The cost was
minimal.
The picture at left shows the character achieved by
the use of special forming in the concrete work.
FINISHED VAULTED ROOF
IN RED: THE FIBER GLASS ROOF FORM

MASTER PLANS
An important document to show the placement of the structures to be
build with the CRH system is the Site Plan.
My concern as an architect is to create an environment where the
residents have access to commercial and professional facilities,
entertainment and good restaurants. Land uses should be close
enough to allow walking or bicycling.
Analysis of the site and contour lines includes slope degree,
orientation, natural drainage, and existing vegetation. This is the
basis for locating structures and services such as waste
management, water recycling and trash disposal. The goal is to
keep the habitat natural and place the buildings to facilitate energy
conservation for low maintenance and durability.

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RAMMED EARTH HOUSES
HOW THE CONCRETE RIB HOUSE WAS BORN
In Calpulalpan, Tlaxcala
Mexican Republic
For Banco de Credito Ejidal
Under Management of Professor Francisco Hernandez y Hernandez

Professor Francisco Hernandez y Hernandez, General Manager of the Banco de Credito Ejidal, give me a commission:
build houses for the poorest people in Mexico, the farmers. It was a big challenge, with no budget for labor and little
money for construction materials. I took the challenge and found the solution.
• For labor, I used the future owners.
• For construction material, I used dirt.
THE CONSTRUCTION SITE AND CONSTRUCTION MATERIAL SOURCE

I made an agreement with the farmers who wanted to have a house: they needed to provide the labor from
beginning to end of the houses. Nobody would know which house will belong to which family. At the end of
construction a drawing would be used to assign each house to a family. Everybody in the family was involved
in construction.
Women were in charge of bringing the food at the site and cheerleading the men.
GRADING, SEWER LINES, ROUGH PLUMBING, TO START.
STOCK PILING DIRT TO USE LATER

After concrete foundation and slab, rocks
were embedded in the concrete to serve
as hold downs for the walls. The Farmers
Bank (Banco Ejidal) sponsoring the
project was paying for the cement, but
sand, gravel, and rocks were collected by
the farmers. They were lucky because a
little creek with abundant rock was close.
ROCK DOWELS DETAIL
In the photo at right a
stock of dirt is visible in
the foreground. Behind
the farmers a wall can be
seen. A Bank truck is
delivering cement.
Farmers build a shade
structure at the right to
have “tacos” with the
family. Even the children
come to discuss the
construction advance and
dream of having their own
bedroom and a bathroom
with out going outside.
It was very rewarding
doing this project.

Panoramic view of metal forms strong enough to accept the impact of the compactor when earth is rammed.
Behind the form are walls from which the forms were removed. A village cornfield is growing in the rear.

This is a detail showing
at the rear some forms in
place, and a portion of
wall where is an opening
for a window.
Note the lower part of the
wall which has masonry
concrete to prevent
damage from rain.
While observing this
process I started to think
about using concrete
poured in forms in a
similar way. Thus, 40
years ago the ides for
the Concrete Rib House
began.
This system of rammed
earth construction give
dwellings to 30 families
in the rural area of
Calpulalpan, a village in
the State of Tlaxcala,
Mexico.
As a result of their
experience in teamwork,
after moving into the
houses, the farmers
pooled resources and
bought agricultural
machinery and quickly
became prosperous.

ONE OF THE FINISHED HOUSES HAS THE OWNER ENJOYING LIFE.
THE FINISHING WAS USING AN EMULSION OF WATER AND LIME SPRAYED AGAINST
THE WALLS, VYNIL PAINT AS ACCENT (THE BANK PROVIDED FOR THE PAINT)

ANOTHER HOUSE, DIFFERENT FLOOR PLAN

The walls have 2 coats of lime as finish, the color accents done with vinyl paint.
ONE BEDROOM OF THE THREE

Dining area with furniture designed by me and built by the
farmers. The finish: crude oil dissolved in gasoline.
Joists concrete and metal U shape exterior reinforcement
roof expanded metal lath with cement plaster (see next pg)

I designed innovative joists built with the steel reinforcement
in the exterior, like crabs. U-shaped bent steel has
connectors welded in the interior bottom. I also used this
design for a prefabricated school in Cuernavaca for the
Committee to Build Schools. When filled with concrete it
works as a beam; the tension stress is resisted by the
exposed steel. It avoids the destruction of trees for lumber,
and makes the house fire resistant, at a low cost.
Some of the 30 houses built with Rammed Earth, shown during construction

After building all the houses with rammed earth, I
could not stop thinking about taking a shot at building
the walls with poured concrete. The results are shown
at left, just after taking the metal forms off the walls.
Note the header with exterior metal reinforcement,
similar to the joists described on the previous page.
The picture below shows the structure of a house built
in the 1960s with poured-in-place concrete. A similar
system was used by the Romans around 2,000 years
ago.
It is interesting to
note that the
Anasazi, builders of
Chaco Canyon,
New Mexico, used
a similar system
with stone walls as
forming and mud
as bonding for a
sort of masonry.
Their structures,
built around 700
ago, stand to awe
tourists today.
Concrete walls experiment

CIUDAD AZTECA
7,500 houses built
In 15 months
8 schools, shopping center, offices
Ciudad Azteca was a development managed by an aggressive young business man: Mr.
Norberto Kanner, who create a real city for workers. I had the opportunity of building with my
system of poured-in-place concrete. My effective building system contributed to the success of
Mr Kanner’s Norka development project.

This experience was managing
the construction of 7,500 houses
using my poured-in-place
masonry system.
The houses needed to be
affordable, and the system
accomplished this because I
used the abundant local stone
for 30% of the volume of the
concrete walls. This resulted in
huge savings on materials cost.
The system is very effective if
modified according to the
conditions of materials and labor
availability.
In this job wood forms were used; 25 sets of forms
delivered 25 houses every day to buyers.
It was gratifying to me to see the expression of
happiness on the faces of the buyers moving into their
new homes, with the children choosing their bedrooms
and placing their toys with care.
Above, the photo shows the foundation process, with a
finished house in the background. The photo at right
shows several houses in process, some ready for the
roof, other for the finishing touches.
Ciudad Azteca mass produced housing for workers

Concrete Rib House - Complete

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Concrete Rib House - Complete