BEST(Building “Energy Saving” Technology)

Modular Building Systems

Center for Technology Management, Inc.Presenting

A Green Technology Building System

There are two distinct types of structures designed by CTM

I. Light Weight System; using Glass Fiber Reinforced Polymer (GFRP), mostly suitable for Disaster Shelters & Rapid deployment projects, or claddings on high-rise buildings.

II. Heavier System; using Glass Fiber Reinforced Cement composite (GFRC), suitable for more permanent type buildings – residential &/or commercial.

“Modular Building Panels made of Glass Fiber Reinforced Polymer (GFRP) and Insulating Foam Board are lighter, esthetically pleasing, more durable and less expensive than alternate products.”

Composite panels introduced by Center for Technology Management (CTM) provides a structural light-weight panel with better insulation. It provides more flexibility in design, eliminates the need for using wood or reinforcing steel or added insulation. Buildings are erected much faster and less expensively.

This is a high-tech product using glass fibers and polymer matrix as composite materials.

TYPE I – Light Weight System

Summary:Modular Building Panels Nominal 120 cm x 275 cm size

6.7 cm thick

Inner facing surface GFRP 2 m/m textured colored fireproof

Outer facing surface GFRP 2 m/m textured colored weather-resistant

Lightweight47 pounds, compared to 3,100 pounds for concrete

Structural Panel Composite Material insulating value R= 20 2 Hr. fire rating safe, non-toxic earthquake, hurricane resistant

Built-in channels for seal strips, wiring

A radical move from

Mass Production to Mass Customization

To Reduce costs & Increase design flexibility

Glass Fiber Reinforced Concrete(GFRC)

TYPE II – Structural Panel System

“Modular Building Panels made of GFRC and Perlite concrete/or Foam are lighter, esthetically pleasing, more durable and less expensive than plain concrete panels.”

Perlite provides a structural light-weight concrete – lower panel weight and better insulation. It provides more flexibility in design, eliminates the need for reinforcing steel or added insulation. Buildings are erected much faster and less expensively.

This is a high-tech product using glass fibers and cement matrix as composite materials.

A Typical Standard Design Example

A Typical 2 Bedroom Housing Unit, 1100 Sq.Ft.

Living Area

Kitchen/Dining AreaMaster BR

Bedroom 2

Bathroom

Closets

Electrical & Communications

Modules

Hot & Wet-WallApplication

Modular 4' Panels

Closets

Hot & Wet-Wall Application

Dining Area

Washer/Dryer

HV

AC

10'

2'

A 2-Bedroom Unit in Clusters

“Surgy Clinic”

School

Solid Concrete is not an ideal building solution

• Great compressive strength• Any shape desired• Grows stronger with age• Fire and termite resistant

• Poor tensile strength• Conducts heat• Heavy

• Heavy to handle• Makes heavy buildings

• Energy intensive (cement production)• Limited market range • Expensive Transportation• Environmentally Taxing

PRO CON

Due to Hurricane & Severe Wind Loadings,What happens when a concrete wall is stressed?

External Force

InnerSurface

OuterSurface

undergoesTension

undergoesCompression

small deflection

The problem?

External Force

Tension Compression

Crackleading tocollapse

No problemfor concrete.

Severe problem for concrete, which has low tensile strength.Need to add Steel.

InnerSurface

OuterSurface

underTension,Glass fiberstake the Tension

underCompression

No crack

Add outer layers of Tension-Resistant material

Glass Fiber ReinforcedConcrete (GFRC) layers

Step 1Step 2

Change core to lightweight Perlite Concrete

External Force

Solution: Composite Materials!

What isGlass Fiber Reinforced Concrete?A thin layer of concrete containing glass fibers, which have very high tensile strength. Similar to Plastic fiberglass matrix, except embedded in concrete.

GFRC layer | Insulating concrete core

The GFRC layer, applied with a spray gun, bonds to the fresh backing

What is perlite?

A silicate mineral that pops like popcorn when heated. It expands to 16 times its volume.

Expanded perlite is essentially a foamed mineral bubble.cheap • lightweight • insulating • fire-resistant

What is Perlite Concrete?

A mixture of 65% perlite, 35% Sand & Cement Matrix

Concrete Perlite ConcreteWeight lb/cu ft 150 55Thermal BTU/sq ft/hr 12 1.7Price $/cu yd $125 $42Compression; PSI 3,500 1,800Tensile PSI 250 1,200

Note: The loss of compression strength in the center core is not a significant factor -- no need for high strength in the core.

Buildings can actually be made lighter, using less steel, and with smaller foundations and less framework when built with Perlite Concrete.

• Great compressive strength• Any shape desired• Grows stronger with age• Fire and termite resistant• Great tensile strength• Excellent insulator• Lightweight• Low energy cost• Expanded market range

• Poor tensile strength• Conducts heat• Heavy• Energy intensive• Limited market range

PRO CON

With GFRC & Perlite Concrete Panels,all the CONs of concrete become PROs

In addition:• Improved earthquake, fire, tsunami, hurricane resistance• Faster, less expensive to erect• Extended shipping range• No framing required

• Variety of Color, textured surfaces – no need for outer facing• Lighter buildings with less steelwork, smaller footings• Unlimited design flexibility

Summary:Modular Building Panels Nominal 4’ x 10’ size

6” thick

Inner facing surface GFRC 1/8” thick textured colored fireproof

Outer facing surface GFRC 1/8” thick textured colored weather-resistant

Lightweight750 pounds, compared to 3,100 pounds for concrete

Structural Panel Composite Material insulating value R= 20 2 Hr. fire rating safe, non-toxic earthquake, hurricane resistant

Built-in channels all aroundFor seal strips, wiring

Savings:• Materials• Labor• Erection Speed• Shorter Construction Time• Low Weight, Extended Shipping Range/Costs• Design Flexibility• Environmental Benefits• Better Insulation Properties (R= 15 to 20)• Better Sound Proofing• Resistant to Fire, Termite, Earthquake, Hurricane

A typical Construction CycleFor a 12-story Office Building

2 years 1/2 year 18 months

Regional contracts CTM Modular Precast System

CTM Modular Design

28-Month Cycle Timewith CTM Products

DESIGN & Permits CONTRACT CONSTRUCT

4 - Year Cycle Timewith present conventional methods

1yr 4 Mo 1 year

Financial Savings

• 1 step• 1 craft• 1 week• $144,000 *

• 5 steps• 4 crafts• 6 weeks• $538,000

Concrete panel Concrete block GFRC panel

• Additional savings of Interest on Construction Loans, • No need for steel framing (up to 2 stories), smaller footings• Easier to handle, and lighter building,• Earthquake / hurricane / tsunami / fire resistance, • Increased labor productivity.

Crafts include Drywalls, masons, insulators, equipment operators (Estimates are based on a 120 x 40 ft, 4 story building shell)

* At production cost; market price to be determined

• 4 steps• 3 crafts• 3 weeks• $422,000

Products Cost Summary

Panels, 4’ x 10’ x 6” Floor Decks, 4’ x 8’

(one layer GFRC)

Material: $48.00 $40.00Direct Labor $64.80 $33.60Joinery $34.00 ---------TOTALS: $146.80 $73.60

CTM TechnologiesEnergy Saving Building System

Products: External Wall Panels & Floor Decks

Production Plant Costs: $25 milProduction Labor rate = $28/hr

In one year,Plant Operating @ 80% Capacity can supply:

• 120 Town Houses• 80 Single Family Homes• 4 Conventional High Rises• 5 Shopping Centers; 80’ x 480’ long; 24 stores (producing 1.2 million sq.ft. of buildings/year)

Generating Savings of about $8.5 mil/year+

Yield a Net Profit (before taxes) of about $11 mil/year

Samples of existing buildingsSingle story & High-Rise

What is the advantage?Concrete panel

Gypsum wallboard Insulation Concrete panel Facing panel

CTM panel

All in OneOperation

Gypsum wallboard Insulation Concrete block

Mortar Facing panel

Concrete block

Surface Finishes(GFRC)

Inner Surface Appearance • Plain, smooth cement• Stone• Wood• Wallboard• Tile• Colors, textures

Outer Surface Appearance • Plain concrete• Stone• Stucco (shown here)• Brick• Aggregates• Wood• Inlays• Colors, textures

A typical composite panel(GFRP or GFRC)

Surface Finishes • Plain, smooth cement• Stone• Wood• Brick• Stucco in different Colors, textures

Structure • Stress Skins• Insulating Core• Size: 4’ x 10’ x 4”-6” thick• Weight: 40 lbs to 1200 lbs

ConstructionA crane sets the panels in place.

Panels are locked together using steel bars (joinery)

Panels are supported by special connectors

No other operations are required.

ONE-STEP INSTALLATION

Production & Delivery

1. Automatic spray of GFRC layer into form

2. Perlite concrete is poured in and leveled

3. Top layer of GFRC is added

4. Forms are stacked to cure for 10 hours

5. Shipment.

Products being marketed, using CTM Technologies

1) Customized Wall Panels – Residential & Office Buildings

2) Customized Ceiling/Floor Panels - “ “ “

3) Insulated Claddings; stone/brick patterns4) Disaster Shelters, using light composites

Market Potentials

• Application for Disaster Shelters• Residential, community, commercial, industrial, government, and military markets

• Huge new markets created by new building codes in tsunami, hurricane, earthquake areas

• International markets

• Diverse building components: roof panels; interior walls; structural external panels

• Disaster reconstruction projects

• Energy efficient building projects

Financial Summaries

• Materials cost $2.95 / sq.ft.• Total production cost $6.85 / sq.ft.• Market price $13-20 / sq.ft.• U.S. target market size 29 million pnl/yr.

1.2 bil.sq.ft./yr.• Potential Revenues /Factory $57.6

million/yr.• Potential Net Operating Profit $24.7 million/yr.

(at $12/Sq.Ft. market price)

For a typical Factory; 120,000 panels/yr @ $12/sq.ft.

Advantages of a Manufacturing Facility

Considering the rapid growth of energy costs, and the desire for “Energy Saving” products, BEST products can serve such a

market with the following advantages:

• Increased job opportunities• Lower Construction Costs• Higher Speed of Construction• Less Cement is used for Buildings• Tremendous Savings of Energy • Higher Building Quality & Durability • Lower Maintenance Costs• Expanded Market Reach• Increased Export Potential

What’s needed?Start-up tasks

• Meeting local Building Codes

• Fabricate panels for marketing

• Carry out a pilot project – Design & Build

• Secure sales agreements

• Startup financing

Production

• Factory at U.S. location: 120,000 panel/year capacity

• Equipment and setup

Capital financing required: $22 mil to 28 million, depending on capacity

65% Debt, 35% Equity at 122% IRR

MANAGEMENT

Dr. B. Bahramian is the founder and developer of BEST building system. He has 30 years of experience in the design, development and manufacturing of building systems and holds a number of patents and copyrights in this field. He has been responsible for a number of development projects involving design and construction of housing projects and commercial buildings. He graduated from University of Birmingham, England with Ph.D. in Civil Engineering, and M.A. in Political Economics (major in Business Administration) from the University of Dayton, Ohio. He is serving as a Director & Professor of Construction Management Technology at University of Maryland.