Precasting overview

	A	B	C	D	E	F	G	H	I	J	K	L	M	N	O	P	Q	R	S	T	U	V
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3
4																	cart length= 99"
5	Panel Sizes	Qnty molds	Conc/mold	Total wt conc	sq ft/piece	Total sq ft	Exp Steels	$/SF	Sales $	Labor	Total min	Inches rebar	Total rebar	Mold size	Total mold sf	mold size	mold/cart	carts #	cart dimen
6	12x16	10	21	210	1.33	13	10	10	$133	12	120	0	0	285	2850	15x19	8	2	90x19
7	18x16	2	30	60	2.00	4	4	9	$36	15	30	0	0	399	798	21x19	2	1	42x19	2 27x19
8	24x16	160	41	6560	2.67	427	320	8	$3,418	15	2400	0	0	513	82080	27x19	5	32	27x95	54x19sp
9	36x16	12	53	636	4.00	48	36	10	$480	18	216	60	720	741	8892	39x19	5	3	39x95
10	48x8	2	44	88	2.67	5	8	12	$64	22	44	80	160	561	1122	51x11	2	1	51x22
11	60x8	8	55	440	3.33	27	40	13	$347	24	192	100	800	693	5544	63x11	2	4	63x22
12	72x8	10	65	650	4.00	40	60	13	$520	28	280	120	1200	825	8250	75x11	2	5	75x22
13	24x12wf	2	32	64	2.00	4	2	10	$40	16	32	0	0	405	810	27x15	0	0
14	36x12wf	2	48	96	3.00	6	4	11	$66	20	40	60	120	585	1170	39x15	4	1	66x30
15	44x12wf	2	60	120	3.67	7	6	11	$81	22	44	80	160	705	1410	47x15	0	0
16	48x12wf	2	68	136	4.00	8	8	11	$88	24	48	88	176	765	1530	51x15	4	1	98x30
17	86x12df	2	110	220	7.17	14	14	14	$201	36	72	162	324	1335	2670	89x15
18	94x12 df	2	130	260	7.83	16	16	15	$235	40	80	180	360	1455	2910	97x15
19	ext quoin	11	68	748	4.00	44	11	25	$1,100	45	495	80	880	405	4455	27x19
20	int quoin	14	78	1092	4.44	62	42	23	$1,431	40	560	84	1176	435	6090	29x19
21	8x12	2	12	24	0.67	1	2	10	$13	12	24	0	0	165	330	11x15
22
23	Total	243	Pounds	11404		727	583		$8,252		4677		6076		130911
24			cubic ft	79						Hours =	77.95		506.3333333		909.1041667
25			cubic yds	3						Hours/shift	7		25.31666667		1.249807151
26		Cost of concrete/yd =		$160						No. workers=	11.13571429		$10
27		total con		480						$/hr	$25		$260
28		Helix fiber		$39						12 people x 8	96		Two people 4 hours to cut
29		Expanded steel =		5						Total wages=	$2,400		8 hours total to cut rebar
30		$/sheet =		40									200
31		Expanded cost =		$200
32		7 hours for 5 sheets							total costs=	$4,042
33		Labor to cut 600 pieces=		200					Profit =	$4,210		240 days operation per year		profit	$1,010,429.87
34
35		Styrofoam $/cubic foot=		2
36		Cubic ft styro =		31.45931034
37		Styro cost =		$63					118.3215957	280
38		Hours to cut=		7
39		Wages =		200
40						If cellular concrete is used instead, one sack portland makes 10 cubic feet with a 0.5 water cement ratio and addition of foam
41					12x16	18x16	24x16	36x16	48x8	60x8	72x8	24x12wf	36x12wf	44x12wf	48x12wf	86x12df	94x12df	ext quoin	int quoin	8x12
42	Labor processes starting from de-molding to refilling
43	1. Extract cart five molds from consolidation area				20	20	20	20	20	20	20	20	20	20	20	20	20	20	20	20	320	5.3
44	2. Remove ratchet strap				6	6	6	8	9	10	12	6	8	9	40	15	18	30	20	8	211	3.5
45	3. Hang ratchet strap on cart hooks				5	5	5	5	7	7	9	5	5	7	7	10	10	20	20	5	132	2.2
46	4. Place mold on removal jig				8	5	5	7	8	9	10	5	6	7	8	20	28	20	24	4	174	2.9
47	5. Remove screws holding expanded steels				8	8	12	18	24	30	36	0	6	18	24	48	54	20	24	6	336	5.6
48	6. Remove waffle jig				10	8	10	15	20	25	30	8	15	28	32	40	50	120	100	5	516	8.6
49	7. Place waffle jig on cart hook				5	5	6	8	12	14	16	8	10	12	13	20	25	30	30	5	219	3.7
50	8. Using removal jig, remove one side				12	15	17	22	26	28	30	14	16	20	22	30	32	30	30	8	352	5.9
51	9. Place mold side on cart shelf				6	7	8	9	10	11	12	7	8	10	12	14	16	30	30	7	197	3.3
52	10. Remove panel from mold				8	9	10	12	16	18	20	9	12	14	16	25	30	30	30	5	264	4.4
53	11. Place panel on conveyor				8	6	7	8	9	10	11	6	7	8	9	12	14	20	20	5	160	2.7
54	12. Clean mold				30	32	34	40	50	60	66	34	40	46	48	80	90	600	600	30	1880	31.3
55	13. Apply release				20	30	34	40	50	60	66	34	40	46	48	80	90	600	600	30	1868	31.1
56	14. Reinstall mold side				20	10	12	14	20	22	24	10	12	14	16	30	36	600	600	20	1460	24.3
57	15. Install ratchet strap				12	14	16	18	22	24	30	12	16	22	24	28	30	400	400	12	1080	18.0
58	16. Place truing jig into mold				6	8	10	14	16	18	20	10	14	16	18	20	22	120	120	8	440	7.3
59	17. Tighten ratchet strap				10	12	14	16	18	20	22	10	12	12	14	16	18	120	120	8	442	7.4
60	18. Inspect mold accuracy				6	8	10	12	14	16	18	8	10	12	14	20	24	180	180	4	536	8.9
61	19. Remove truing jig				10	12	14	16	18	20	22	12	14	16	18	20	22	60	60	10	344	5.7
62	20. Place mold on cart				8	8	10	12	14	16	18	8	10	12	14	16	18	20	20	6	210	3.5
63	21. Take cart to pouring area				12	14	16	18	30	36	40	14	16	18	20	30	36	40	40	12	392	6.5
64	22. Assemble waffle jig				30	30	36	42	80	90	100	30	36	48	50	80	90	180	180	30	1132	18.9
65	23. Place on scale				10	12	14	16	20	22	24	10	12	14	16	18	20	24	24	10	266	4.4
66	24. Fill with concrete				6	8	10	12	16	18	20	8	10	12	14	30	36	240	200	6	646	10.8
67	25. Move to vibrator				8	8	10	12	14	16	18	8	10	12	14	16	18	20	20	8	212	3.5
68	26. Vibrate waffle into mold				8	0	10	12	14	16	18	8	12	14	16	20	24	20	40	8	240	4.0
69	27. Secure waffle				10	10	12	14	16	18	20	10	14	16	18	20	22	6	20	8	234	3.9
70	28. Remove to cart or conveyor				8	9	10	12	14	16	18	8	12	14	16	24	30	30	40	8	269	4.5
71	29. Store cart for curing				30	36	40	50	60	70	80	36	40	50	60	70	80	80	80	30	892	14.9
72
73					340	355	418	502	647	740	830	358	443	547	641	872	1003	3710	3692	326
74				Minutes	5.7	5.9	7.0	8.4	10.8	12.3	13.8	6.0	7.4	9.1	10.7	14.5	16.7	61.8	61.5	5.4
75			hours all molds		0.94	0.03	18.58	1.67	0.36	1.64	2.31	0.20	0.25	0.30	0.36	0.48	0.56	11.34	14.36	0.18
76																					53.56
77					12x16	18x16	24x16	36x16	48x8	60x8	72x8	24x12wf	36x12wf	44x12wf	48x12wf	86x12df	94x12df	ext quoin	int quoin	8x12
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79
80	Size needed for one hundred million dollars per year sales
81
82	Sales per unit quantity of molds from above =				$8,252
83	100000000 revenue goal
84	Number of units =				12,118
85	two shifts per day				6059
86	square feet space needed per unit				1818
87
88	Assume 120' x 60' building = 7200 sq ft
89
90	One building can produce =			3.959331313		Say 4 units
91	If two shifts per day then 8 units per day
92	240 days annual production, number of units produced =					1920
93
94	Number of producing plants =			6.311506047
95
96	Assume 2500 sq ft homes
97	Rule of thumb, 3.3 sq ft of panel per sf floorplan
98	8250	sf panel per home
99
100	9776196	sq ft of panel produced by seven plants, two shifts per day, over 240 days