While building a new project home will usually be cheaper than a renovation, the launch of a new affordable housing prototype sheds some light on the design rules for cost-effective building.
You can’t really compare what your friends paid for their new project home with the quoted cost of your renovation. A new home - particularly one built by a large volume builder - is quite a different beast to your renovation.
In Chapter 1 of The Renovator’s Survival Guide I delve into the reasons why the costs of one are so much less than the costs of the other. Repeatability is one factor and bulk purchasing arrangements are another. In contrast, your renovation is a unique, customised design.
The cost differences are considerable. it might be $900 a square metre for your friend’s project home and $3,500 a square metre for your renovation. While there are some other choices - knock down and rebuild could be cheaper per square metre but more in total - is there anything you can do at the design stage to reduce the costs of construction?
I interviewed designer Brett Blacklow recently, just prior to the launch of The Smarter Small Home - a prototype of an affordable home. (The creators were aiming to produce a new home that could be sold for less than $300,000 - this is house and land. While a big driver in reducing cost is a smaller lot and therefore home, the design challenge was how to make that small home highly livable.) I know the home he designed is a new one, but I thought there were a number of points he made that were useful to renovators.
1. Choose the economical materials first
Does this seem revolutionary? Blacklow says he tried to design the structure of the house and the floor plate around the limitations of their economical materials.”Typically no-one approaches it like that,” he says. “The builder or designer comes up with a floor plan and then he works out how to make it stand up.”
Blacklow feels this is a recipe for adding all sorts of costs that aren’t immediately obvious into a building, because the designer or builder has to make the structure work. He says that with his approach “you can pare down the costs”. One example of where they did this was with the choice of floor joists. He designed the home around the most cost-effective joists he could find - 245mm by 90mm Hyne ply I-beams with a retail cost of around $8 a square metre compared with two of three times that amount for hardwood or laminated veneer lumber (LVLs).
2. Design around the size of the materials (and minimise waste)
One of the key elements of the design approach was to design rooms, heights and walls to the size of materials available. “When I buy timber, it has to be in 300mm increments,” says Blacklow. “Plasterboard is two different widths. If I’m not thinking of those things when I’m designing, then I’m potentially buying more than I need and I’m also paying someone to cut it down to the right size.”
In addition, the team has developed the design to incorporate a number of the offcuts that may be generated. For example, they use HardiFlex sheets in certain places, and then use the 600mm offcuts in another. That’s instead of using full sheets and throwing the offcuts away.
“For example, plasterers often line the inside walls by sheeting straight over a window or door and then cutting it out,” Blacklow says. Then half an hour later they need the same size as that or smaller and so they cut off a new piece of plaster.”
Because all the waste on a building site is paid for, it makes sense to minimise it.Typically, skips have to be hired and then transported to a transfer station or recycler and then fees paid on that. On The Smarter Small Home Blacklow’s team aims to reduce the total waste produced by up to 50%.
Heavy brick versus lightweight
Blacklow is well qualified to assess the real costs of construction. When he added up the bill to construct The Smarter Small HomeTM, the total came to just over $140,000 (including GST). He then calculated the cost to build the home substituting the fibre cement products with timber weatherboards and flat sheet ply cladding. He then did another calculation, substituting the piers with an ‘M’class concrete slab on flat ground, brick veneer walls instead of lightweight cladding, and a pitched concrete tiled roof using standard roof trusses. The total costs were $150,808 and $166,261 respectively, including GST.
Of course, what’s important here are the relative costs differences versus the actual numbers - as these will vary according to location and the deals individual builders make. But it does indicate that some types of construction approaches tend to me more cost effective than others. While many builder say that the concrete slab and brick veneer combination is the most cost effective, this is context-dependent.
Blacklow told me that in his view there were a number of key construction choices that tended to drive cost efficiency. Two that could easily be adopted by renovators are:
1. Using screw-in footings.
While a slab on ground requires a level pad, a raised house can be built over a small fall without incurring any real extra cost. That’s because screw-in footings don’t require excavation and don’t produce a big pile of excess soil that needs to be dumped or spread over the remainder of the site. In addition, installing the screw-in footings means two people are there over a half day, whereas a slab uses a number of subcontractor teams and happens over a one to two week period. In addition, the screw-in footings can also lower plumbing costs.Blacklow says this is because a plumber’s charge is slightly cheaper when plumbing suspended pipework under a timber framed floor than it is buried under a slab. Finally, screw-in footings can help ventilation and air flow under the old houses we’re renovating, that often have problems with rising damp.
2. Using lightweight products instead of brick veneer with steel support.
The costs of the brick veneer skin and the requirement for steel support bars over large openings and a set back upper storey makes it a more costly solution than using lightweight sheet products in this context. Blacklow says this is partly because the heavyweight brickwork requires a metal scaffold, not an aluminium one, which is more expensive to hire and the labour time required for brick installation is typically longer than sheet cladding so, again, the scaffold stays up for a much longer period of time and therefore incurs more cost.
Of course many renovations won’t have a scaffold, but they do have small sites on which it’s difficult to fit all the brick pallets that are needed. My neighbour has exactly this problem. He’s having to get his bricks there in two deliveries at least, the chippies won’t work on site at the same time as the brickies, and the whole thing could have gone a lot faster if he’d built using panel products versus brick. By the way - the bricks on the outside wall are having to be laid hand over hand from the inside! My neighbour says he’s paying the brickies double the going rate for that privilege.