5 bedroom, 3 1/2 bath 4100 square foot home
180 mph wind rating, Seismic Zone 3 rating
Interior and exterior SIP walls, SIP roof panels
Exterior / interior wall height 8’, 12’, 24’
Impact windows (installation is included in duration)
Interior and exterior doors (installation not included in duration)
SIP Panel Type: Active Zero Energy Bandwagon HIP MGO SIP wall panels, MGO / OSB SIP Roof Panels
5 man crew, 30 days (6 weeks) to install the complete Active Zero Energy Bandwagon SIP building kit on a framed deck.
First time SIP install – add 30% to crew time estimate
2nd floor is conventional framing and is included in estimate
Estimating by panel count:
Another method for calculating the cost of SIP panel installation is by panel count. When using the panel count method, it is important to understand the efficiency of a typical days work. Considering crew setup time, morning and afternoon breaks, lunch, pickup at the end of the day and other non-productive daily task, actual labor efficiency is about 6 hours per 8 hour shift. For this reason, many SIP installers work 10 hour shifts in order to increase productivity. Once the crew is going, better to keep them setting panels than to stop the momentum, pickup tools and cleanup, then setup again the next morning before you can start setting panels again. Those extra two hours a day setting panels can be some of the most productive hours, as the crew usually develops a rhythm with the setting of the panels. In might take an hour to set the first panel, then you set 7 panels the second hour.
When calculating installation cost by the panel count method, it is important to count each and every panel, regardless of size. Let’s assume that we have a 1200 square foot home with a total of 195 individual wall and roof panels (interior and exterior panels) with a 150 mph wind rated building kit with no seismic considerations. We allow 20 minutes average crew time to set a SIP panel so 195 panels x 20 minutes = 4039 minutes, 4039 / 60 minutes = 67.3 crew hours approximately 8.5 crew days for this install. If your average man hour cost were $35 per hour, $175 per crew hour (5 man crew), the labor cost of this install would be $11,725 (67 hours x $175 crew hour) plus the rental of the tele-handler forklift, scaffolding, tools and equipment plus applicable Contractor insurance, overhead and profit. For this size project, you would add one crew day for seismic design and 1 additional day for a 180 mph wind rating kit design. For the 120 mph wind rating kit design, you would deduct 2 crew days installation time from the above.
The panel count method of estimating assumes ground level installations with good access around the building pad and adequate material staging area. Restricted site access and limited staging area must be considered when pricing the difficulty of the project. In addition, designs with large or multiple window and door openings will require more crew hours as impact openings require more post, straps, anchors and connections at the top and bottom plates for each opening. The above assumes an average skilled crew of one lead carpenter, one carpenter and 3 helpers. Crews with a higher skill level will be more efficient and complete the installations in shorter durations. On large projects of 20 or more common homes, installers can setup production installation crews with specific task of installing floor plates, installing walls, setting roof panels, installing window and doors. Production crews can develop a very efficient field assembly line of SIP home installation that can reduce installation times as shown in the case studies by as much as 35% when compared to the duration (cost) of a single home installation as depicted in the case studies presented above.