MANAGEMENT By Jason Kulvinskas
Mastering Metal Deck Estimates Warning signs that can slow production and increase labor or material costs
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etal decking installation is the most labor-intensive aspect of a steel erector’s scope, and numerous factors can directly impact labor costs. This makes an accurate installation estimate crucial for a successful steel erection bid. The process begins with take-offs, where I quickly review the complete set of structural drawings. This provides an overview of the building’s shape, size, and complexity. I assess if the project has multiple buildings or multi-stories. We rely on Bluebeam Software to do take-offs, which has been an invaluable tool for our company. After initial review, I identify critical details such as deck type, deck gage, attachment methods and patterns, elevations, and joist or beam spans. Below are some key considerations to take into account in order to make an accurate estimate.
Deck Specifications There are several considerations with metal decking that influence labor costs. The deck type, gage, attachment methods and patterns are examples of factors that help develop your estimate. Specialty deck and heavier gages typically require more labor, which should be factored into your bid. Deck Type: Most roof decks are 1.5” B Deck or 3” N Deck, while floor decks are typically 1.5”, 2” or 3” composite deck. Pricing standard deck is straightforward. However, specialty decks, especially those that are exposed and require uniform spacing, take more time to install. Jason Kulvinskas is Vice President of GardnerWatson Decking, Oldsmar, Florida, where he has worked for more than 16 years.
16 | THE STEEL ERECTORS ASSOCIATION OF AMERICA
Examples of specialty decks include Epic Super Wideck with a 9” Depth or Verco 3.5” Dovetail Deck. These often need to be installed one sheet at a time, sometimes requiring a crane to lift them in place due to their weight. Production rates on these non-standard decks can be 50-85% lower than for standard decks. Deck Gage: Deck gage also affects production. While 18, 20, and 22 gage is common, 18 gage deck is heavier, and it can slow production. Less common 16 gage deck is very heavy making it difficult to break bundles, as the sheets tend to stick together due to their weight. This requires additional manpower to avoid overworking the crew and production reduction is significant.
Account for Attachment Understanding the specified attachment methods and patterns is essential for accurate estimating. These details can significantly impact both material costs and labor requirements. Non-standard methods or patterns may increase project time and expense, but there is often room for negotiation with the Engineer of Record (EOR) to implement more efficient alternatives. Attachment Method: Most plans specify puddle welds, with sidelaps secured by #10 Tek screws. Recently, there's a trend for large warehouses to require Hilti pins for attachment. While more expensive, they reduce labor costs due to faster installation, making them a recommended choice for such projects. When #12 Tek 5 screws are specified, we often request a spec change with the EOR. Attaching with screws is more time-consuming to install than puddle welds or Hiti pins. If the deck is attached to purlins or thin joists, screws
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❹ are the better option, but for other cases, switching to an alternative can save money and expedite the schedule. For sidelaps, button punching or using the Verco Punchlok II tool doesn't typically increase labor. However, when welding sidelaps is required, labor costs rise significantly. Seam welds are more difficult and time consuming than putting in screws. If possible, we negotiate to switch from seam welds to sidelap screws. Occasionally, the EOR will allow the same quantity of sidelap attachments that was originally spec’d for welds to be used for screws. However, due to higher shear values derived from seam welds we usually put in several more screws to equal the original patterns. For instance, instead of three seam welds per span you may need 18 screws per span. In our experience, welding sidelaps on