Precasting overview
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cart length= 99"
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Panel SizesQnty moldsConc/mold
Total wt conc
sq ft/piece
Total sq ft
Exp Steels$/SFSales $LaborTotal minInches rebarTotal rebarMold sizeTotal mold sfmold size
mold/cart
carts #
cart dimen
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12x1610212101.33131010$1331212000285285015x19 8290x19
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18x16230602.00449$3615300039979821x192142x192 27x19
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24x161604165602.674273208$3,418152400005138208027x1953227x9554x19sp
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36x1612536364.00483610$4801821660720741889239x195339x95
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48x8244882.675812$64224480160561112251x112151x22
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60x88554403.33274013$34724192100800693554463x112463x22
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72x810656504.00406013$520282801201200825825075x112575x22
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24x12wf232642.004210$4016320040581027x1500
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36x12wf248963.006411$66204060120585117039x154166x30
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44x12wf2601203.677611$81224480160705141047x1500
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48x12wf2681364.008811$88244888176765153051x154198x30
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86x12df21102207.17141414$20136721623241335267089x15
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94x12 df21302607.83161615$23540801803601455291097x15
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ext quoin11687484.00441125$1,1004549580880405445527x19
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int quoin147810924.44624223$1,43140560841176435609029x19
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8x12212240.671210$1312240016533011x15
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Total 243 Pounds 11404727583$8,25246776076130911
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cubic ft79Hours =77.95506.3333333909.1041667
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cubic yds3Hours/shift725.316666671.249807151
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Cost of concrete/yd =
$160
No. workers=
11.13571429$10
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total con480$/hr$25$260
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Helix fiber $39
12 people x 8
96
Two people 4 hours to cut
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Expanded steel =
5
Total wages=
$2,400
8 hours total to cut rebar
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$/sheet =40200
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Expanded cost =
$200
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7 hours for 5 sheets
total costs=$4,042
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Labor to cut 600 pieces=
200Profit =$4,210
240 days operation per year
profit $1,010,429.87
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Styrofoam $/cubic foot=
2
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Cubic ft styro =
31.45931034
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Styro cost =
$63118.3215957280
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Hours to cut=
7
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Wages =200
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If cellular concrete is used instead, one sack portland makes 10 cubic feet with a 0.5 water cement ratio and addition of foam
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12x1618x1624x1636x1648x860x872x824x12wf36x12wf44x12wf48x12wf86x12df94x12dfext quoinint quoin8x12
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Labor processes starting from de-molding to refilling
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1. Extract cart five molds from consolidation area
202020202020202020202020202020203205.3
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2. Remove ratchet strap
666891012689401518302082113.5
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3. Hang ratchet strap on cart hooks
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4. Place mold on removal jig
8557891056782028202441742.9
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5. Remove screws holding expanded steels
8812182430360618244854202463365.6
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6. Remove waffle jig
10810152025308152832405012010055168.6
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7. Place waffle jig on cart hook
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8. Using removal jig, remove one side
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9. Place mold side on cart shelf
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10. Remove panel from mold
89101216182091214162530303052644.4
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11. Place panel on conveyor
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12. Clean mold
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13. Apply release
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14. Reinstall mold side
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15. Install ratchet strap
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16. Place truing jig into mold
68101416182010141618202212012084407.3
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17. Tighten ratchet strap
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18. Inspect mold accuracy
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19. Remove truing jig
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20. Place mold on cart
88101214161881012141618202062103.5
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21. Take cart to pouring area
121416183036401416182030364040123926.5
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22. Assemble waffle jig
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23. Place on scale
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24. Fill with concrete
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25. Move to vibrator
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26. Vibrate waffle into mold
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27. Secure waffle
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28. Remove to cart or conveyor
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29. Store cart for curing
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340355418502647740830358443547641872100337103692326
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Minutes5.75.97.08.410.812.313.86.07.49.110.714.516.761.861.55.4
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hours all molds
0.940.0318.581.670.361.642.310.200.250.300.360.480.5611.3414.360.18
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53.56
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12x1618x1624x1636x1648x860x872x824x12wf36x12wf44x12wf48x12wf86x12df94x12dfext quoinint quoin8x12
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Size needed for one hundred million dollars per year sales
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Sales per unit quantity of molds from above =
$8,252
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100000000 revenue goal
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Number of units =
12,118
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two shifts per day
6059
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square feet space needed per unit
1818
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Assume 120' x 60' building = 7200 sq ft
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One building can produce =
3.959331313
Say 4 units
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If two shifts per day then 8 units per day
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240 days annual production, number of units produced =
1920
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Number of producing plants =
6.311506047
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Assume 2500 sq ft homes
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Rule of thumb, 3.3 sq ft of panel per sf floorplan
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8250
sf panel per home
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100
9776196
sq ft of panel produced by seven plants, two shifts per day, over 240 days
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