|
Study to Determine Life Cycle Costing for Sports Flooring
A Summary of Findings, Copyright MFMA 1999.
Purpose of the Study
The issue of life cycle costing is a critical evaluation criterion for facility owners and managers in the comparison and selection of gymnasium flooring materials. The purpose of this study is to determine life cycle costs for the most frequently specified materials: maple and synthetic flooring. The study was designed and conducted between December 1993 and February 1994 by Ducker Research Company, Inc., of Birmingham, Michigan, specialists in industrial marketing research. Funding was provided by the Maple Flooring Manufacturers Association.
Study Objectives
- To obtain and evaluate material, installation, and maintenance costs associated with maple flooring, PVC, and poured urethane flooring.
- To obtain cost estimates in several forms including per square foot charges and hourly rates with corresponding labor hours for each maintenance procedure.
- To calculate total annual costs for each type of flooring by cost category:
- Initial cost: total installed cost for a standard floor size of 10,000 square feet, life expectancy, and initial cost amortized over the life of each floor type.
- Major refinishing cost: total refinishing costs for a 10,00 foot floor, life expectancy of the refinished floor and total costs amortized over the life of the floor.
- Cost for daily maintenance: material and labor costs over a one year period.
- Other maintenance procedures: material and labor costs for other procedures that take place throughout the year or the life of the floor.
- Report total costs associated with each type of sports floor on an annual basis.
Methodology
Total installed costs and maintenance costs were obtained from end users (owners and maintenance personnel at primary schools, secondary schools, and colleges/universities) as well as contractors. Contractor interviews were used to verify information obtained from end users since contractors are generally more familiar with current installation and maintenance costs. Information was gathered through in-depth telephone interviews. Unprompted and prompted discussion were utilized to allow for qualitative as well as quantitative responses. In total, 145 interviews were conducted to complete this study as follows:
| Interviews Conducted |
| Respondent Type | Number of Respondents |
| Building Owners/Maintenance Personnel | 110 |
| Contractors | 35 |
| Total | 145 |
| Respondent Profile -- End Use |
| Respondent Type | Number of Respondents |
| Primary | 22 |
| Secondary | 48 |
| College/University | 40 |
| Total | 110 |
| Respondent Profile -- Region |
| Region | Number of Respondents |
| Northeast | 22 |
| South | 24 |
| West | 24 |
| Midwest | 40 |
| Total | 110 |
Maintenance schedules were found to vary by level of school with primary and secondary schools following less rigorous schedules than colleges and universities. However, for the purpose of this study, annual costs were based on manufacturers' recommended maintenance procedures. Costs were calculated on a per-square-foot basis and expanded to estimate annual costs based on the frequency of each procedure. Square foot charges will not vary by type of school. However, the frequency of conducting any one of the maintenance procedures will vary.
Life Cycle Cost Analysis
Maple Flooring
Based on an average sports floor of 10,000 square feet, annual costs for maple flooring are shown in the table below. For these floors, the following maintenance schedule is common:
Daily maintenance primarily consisting of one dust mopping*.
Screening, cleaning, and recoating conducted on an annual basis.
Major sanding, sealing, and resurfacing conducted once every ten years.
It is important to note that respondents report life expectancy of maple flooring to average 38 years. This average is used in the calculations below. Annual costs include materials and labor.
| Annual Costs Associated with Maple Sports Flooring |
| Maintenance Procedure | Annual Cost |
| Total Install Cost (Strip Flooring) $81,300: 38 yrs Life Expectancy | $2,139 |
| Daily Maintenance, Dust Mopping 174 hrs per year @ $12/hr | $2,088 |
| Annual Maintenance, Screening and Recoating | $2,800 |
| Major Maintenance, Refinishing $10,700: 10 yrs Life Expectancy | $845 |
| Total | $7,872 |
*Several respondents reported conducting dust mopping more than once a day, but these costs are not factored. A small number of respondents reports cleaning with a damp mop, a procedure not recommended for maple flooring: this cost was not factored into the study.
Synthetic Flooring
This type of flooring is represent by PVC and poured urethane. When evaluating life cycle costing for synthetic flooring, the following recommended maintenance procedures are used:
Daily mopping, wet or dry.
Bi-weekly scrubbing with a chemical cleaner.
Quarterly scrubbing and recoating.
Annual stripping and recoating.
PVC
Annual costs for PVC are calculated on an average life expectancy of 15 years. Respondents report that these floors would be replaced rather than resurfaced after 15 years. Annual costs include materials and labor.
| Annual Costs Associated with PVC Sports Flooring |
| Maintenance Procedure | Annual Cost |
| Total Install Cost $65,000: 15 yrs Life Expectancy | $4,333 |
| Daily Maintenance, Mopping 174 hrs per year @ $12/hr | $2,088 |
| Bi-Weekly Maintenance, Scrub with Chemical Cleaner | $1,848 |
| Quarterly Maintenance, Scrub and Recoat | $1,230 |
| Annual Maintenance, Strip and Recoat | $1,966 |
| Total | $11,465 |
Poured Urethane
The major difference between poured urethane and PVC is urethane 38-year life expectancy when it is resurfaced every ten years. Annual costs include materials and labor.
| Annual Costs Associated with Poured Urethane Sports Flooring |
| Maintenance Procedure | Annual Cost |
| Total Installed Cost $50,000: 38 yrs Life Expectancy | $1,316 |
| Daily Maintenance, Mopping 174 hrs per year @ $12/hr | $2,088 |
| Bi-Weekly Maintenance, Scrub with Chemical Cleaner | $1,848 |
| Quarterly Maintenance, Scrub and Recoat | $1,230 |
| Annual Maintenance, Strip and Recoat | $1,966 |
| Major Maintenance $32,500: 10 yrs Life Expectancy | $2,566 |
| Total | $11,014 |
Total Life Cycle Cost Analysis
When comparing the life cycle cost of maple flooring to that of PVC and poured urethane, maple flooring shows a significant advantage. The life cycle cost of PVC is 42% higher than maple flooring. In addition, the life expectancy of one maple floor is two and one half times that of a PVC floor. Assuming a 38 year life span, one maple floor is the equivalent of more than two PVC floors.
Likewise, the life cycle cost of poured urethane flooring is 40% higher than that of maple flooring.
| Life Cycle Cost Analysis (Model: 10,000 Square Feet) |
| Influencing Factors | Maple | PVC | Poured Urethane |
| Total Installed Costs (amortized) | $2,139 | $4,333 | $1,316 |
| Daily Maintenance | $2,088 | $2,088 | $2,088 |
| Bi-Weekly Maintenance | -- | $1,848 | $1,848 |
| Quarterly Maintenance | -- | $1,230 | $1,230 |
| Major Maintenance (amortized) | $845 | -- | $2,566 |
| Life Expectancy | 38 yrs | 15 yrs | 38 yrs |
| Total Annual Cost | $7,872 | $11,465 | $11,014 |
Qualitative Findings
Installation Costs
The majority of respondents report that synthetic flooring is less expensive to install than maple. However, on a long term basis respondents indicate that maple floors have a longer useful life than synthetic floors. Many respondents report dissatisfaction with their facility's previous decision to contain costs by installing synthetic floors. Moreover, the perception that synthetic floors are comparable in performance and length of useful life is being questioned by end users:
"Even though I know maple floors cost more up front than synthetic floors, I'd rather pay the higher cost. Synthetics do not last and you are either replacing them in 15 years or spending a lot of money refinishing them - if they are salvageable." --End User
Maintenance
Maintaining the finish, durability and aesthetics of maple floors is reportedly easier and less costly. The majority of respondents agree that, despite the disadvantage of yearly screening, cleaning, and recoating, the proper maintenance of maple floors is well worth it and pays in the long run:
"I'd much rather have maple floors in our school because I know I can make them last forever by correctly maintaining them. Synthetic floors are a guessing game and they do not last nearly as long as maple floors do." --End User
Perceived Maintenance Concerns
Maple
- Water, moisture damage, buckling, warping
- Expansion/contraction due to climate changes
- Finish is easily scratched/marred by street shoes (sand and debris tracked in), black/scuff marks
PVC
- Cracks, especially at the edges, gouges/holes, pieces/chunks "fall out"
- Damage is irreparable
- Floor only lasts 15 or so years and must be replaced, no finish to revive the floor
- Surface wears dramatically
- Floor becomes slippery over time regardless of treatment or finish applied
Urethane
- Cracks, especially at the edges, gouges/holes, pieces/chunks "fall out"
- Applied finishes do not bond with the floor
- Floor loses its aesthetic appeal, no shine, looks dirty
- Floors develop bubbles and begin to peel
- Surface, when worm, becomes soft and mushy, hard to sweep/mop, shoes stick, causes injuries
- Refinishing is expensive
Major Perceived Advantages
Maple
- Ease of maintenance
- Ideal surface for sports floors
- Less frequent injuries
- Durable finish
- Longevity of finish
Synthetic
- Low installation cost
- Good surface for multi-purpose events
- Floors not as affected by climate changes
|
