Opi Residential Manual
Transcript of Opi Residential Manual
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OLDCASTLE
RESIDENTIAL BUILDING SYSTEM
EQUUS DESIGN GROUPARCHITECTS PLANNERS
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TABLE OF CONTENTS
USE OF THI S MANUAL
This Oldcastle Residential Building System manual has been de-signed to assist Owners, Architects, Engineers, and others in-terested in the use of precast concrete building systems for resi-dential buildings. Use of the information in this manual will behelpful as references for the design of multi-family residences,college residence halls and senior residence buildings; however,every project must be designed to meet local site conditionsand other local requirements.
The drawings and other information contained herein are illus-trative only and neither Equus Design Group, Inc. nor OldcastlePrecast, Inc. makes any representations as to their fitness forany specific design or structure, and disclaim any responsibilityfor techniques of application, correctness, interpretations, de-sign methods, modifications or misapplications of these draw-ings and references.
Since no specific project nor overall engineering responsibility isimplied with the use of this manual and the information con-tained within, neither Equus Design Group, Inc. nor OldcastlePrecast, Inc. will be responsible for the failure of any designer to
properly design nor any contractor to properly construct anybuilding.
For more information, visit us at www.oldcastlesystems.com
Introduction to Oldcastle Precast
Residential Planning Principles
Oldcastle Residential BuildingSystem
Architectural & Structural Details Sustainable Design
Case Studies
References & Resources
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THE OLDCASTLE RESIDENTIAL SYSTEMPrecast Building Systems for the 21st Century
A Bu i ld in g Syst em ... Fr om a Sin g le Pr ov ider ... Par t ner in g w it h Cl ien t s...
The Oldcastle Residential Building System is morethan just a kit of precast concrete parts. It is a
method for architects and owners to employ forthe total design and construction of residentialbuildings. It is a system designed for wideapplication in residential markets - multi-familyresidences, college dormitories and seniorresidences.
Oldcastle uses a cooperative team methodology. Ourstaff works closely with owners and architects
throughout the design and building constructionprocess providing expert engineering and technicaladvice and support. Oldcastle Precast BuildingSystems is part of the largest precast concretemanufacturer in the United States. We specializein TOTAL BUILDING SYSTEMS by providing design,pre-fabrication and erection services for wholeresidential buildings. Having a single sourceresponsible for the entire building superstructureand envelope allows owners and architects to makethe changes or adapt the design with less risk, fewer
coordination issues and less site mobilization, whilekeeping costs under control.
Oldcastle works directly with Owners and Architectsfrom project inception and each step of the way
from the initial design to construction completion.Through direct partnerships, Oldcastle representa-tives are able to offer creative methods to saveowners and contractors time and money, and toassist architects and engineers during the designprocess.
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Colleges and universities respond to the housingneeds of different age groups and diverse multi-cultural and economic backgrounds of theirstudents. Similarly, the Oldcastle ResidentialBuilding System is adaptable to a wide variety ofResidence Hall types - dormitories, suites,apartments, studio, and couples housing. The
system can be customized in appearance to suitthe architectural context of various campuses.
Col lege Residen ce Hal ls Sen ior Liv in g ResidencesMult i -Family Residences
The Oldcastle Residential Building System isdesigned for a wide variety of multi-family housingtypes low and row housing, mid-rise and high-rise buildings, and low-income to luxury units.Furthermore, the system can be utilized for moststyles of living standard unit layouts, loft styleunits, skip-stop elevator buildings, terraced
buildings, and contemporary and traditional styles.
The increasing numbers of older people, with theirexpectations for a high quality of life, is creatingthe need for new care and housing options. Therehas been a surge in design of a wide variety ofchoices including long term care, assisted living,communities for active lifestyles, independent livingfacilities, and special needs for dementia and
continuing care. The Oldcastle Residential BuildingSystem is adaptable to meet the needs of mostsenior living lifestyles and designs.
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RESIDENTIALPLANNING PRINCIPLES
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RP.1 Low, Mid & High RiseRP.2 Residential FormsRP.3 Forms in SectionRP.4 Multi-Family ResidentialRP.7 Residence HallsRP.10 Senior ResidencesRP.13 Mixed-Use
RESIDENTIAL
PLANNING PRINCIPLES
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Mid-rise buildings, 4 to 8 stories tall with elevators,are the most common style of multi-family housing.The mid-rise is typically a low, broad, horizontalbuilding in suburban settings.
Mid-Rise High -RiseRow / Lo w -Rise
Low-rise buildings, from 1 to 3 stories high, aretypically found in residential neighborhoods andquiet urban streets, often with no elevator. Buildingtypes include rowhouses, townhouses and studios.
The high-rise, 9 stories and higher, is typically talland narrow, located in downtown, urban settingswhere land and parking are a premium. Often theyare mixed-use occupancies with parking or retail atthe lower levels.
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RESI DENTI AL FORMS
Most residential buildings are organized in commonrecognizable forms. The form of the building(s) isusually determined after the Owner and Architecthave determined the program components anddesired relationships, performed a site and zoninganalysis, and determined the appropriateconstruction type.
The Oldcastle Residential Building System isadaptable to a wide variety of orthogonal or planarforms similar to those illustrated in this section.
The array of form possibilities with a total precastbuilding system provides the owner and architectwith nearly limitless creative opportunities.
STEPPED PLAN FLAT FACADE CRENELLATI ONS PROJECTI ONS I NSERTI ONS
OPEN COURTYARD ROW GALLERY PARALLEL FORMS COLLECTED FORMS
ENCLOSED COURTYARD CROSS CORE CENTRAL CORE
CORNER OFFSET LI NEAR
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LOW -RI SE MI D- RI SE HI GH- RI SE
SKI P-STOPSTEPPED
Low r ise housing (1-3 stories) is often designedas row-houses, with interior stair circulation withinor between units.
Mid- r i se (4-8 stories) and High- r i se (9+ stories)buildings are typically double or single loadedcorridor types serviced by elevators. The double-loaded corridor gives the exterior walls of thebuilding to the units to maximize views and sunlight.The single-loaded ga l le ry corridor places units onone side of the building and is generally for sites
with limited width or particularly desirable views.
Sk ip -s top plans locate a corridor on every secondor fourth floor. The units are typically two stories.Unit entry is from a corridor and an internal stairconnects the floors of the unit.
Advantages of skip-stop include:
potential for cross-ventilation with views andsun exposure on two sides of the building
ability to create two-story high loft type space
less underutilized corridor space
The s tepped , or terraced, configurations are thosewhere the units open to an outdoor terrace spacetypically formed by the top of the unit below.
Advantages of stepped include:
improved views and privacy
ability to comply with zoning restricting building
heights at street or property lines ability to create parking or other non-residential
uses at inner levels where the footprint is larger
P a r k i n g below the living space can increasedesirability, reduce land acquisition, and help in tighturban locations.
GALLERY
COURTYARD FORM W/ PARKI NG
FORMS I N SECTI ON
PARKI NG BELOW
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MULTI-FAMILY
RESIDENTIAL
The Oldcastle Residential Building System is designed toaccommodate the widest range of multi-family housingtypes possible. The fundamental character of the housingis defined by its scale.
High-Rise housing is generally found in urban settings,where high-density housing is allowed by local zoning or-dinances. However, it is also built in areas where the
high-rise configuration offers excellent views or allows thepreservation of significant open space that might other-wise be covered with lower scale housing.
Typical high-rise building configurations include a commonstreet level lobby leading to a central core with elevators,stairs and other vertical elements that serve a limitednumber of units. An increasing number of high-risehousing projects offer other mixed-uses such as retail,professional offices, and, often, below-grade parking.
Mid-Rise housing, as defined in this Manual, is in the 4 to8 stories height range. The buildings are generally broaderin width or length than in height, often covering a largeportion of a city block. The mid-rise requires elevatoraccess that is often placed at approximately the mid-pointof the building serving a double- or single-loaded corridorto the units. Egress stairs are typically located at eachend of the corridor.
Row or Low -R ise hous ing . The townhouse is a verycommon form of row house. Typically 2-4 stories tall, theessential characteristics of the townhouse are direct streetaccess to units or groups of units; both front and rearexposures; and shared common walls with adjacent units.Parking is typically on grade or at the street outside thetownhouse.
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Oldcastle Residential Building Systems arecapable of providing total precast structuralsystems for buildings up to 18 stories andhigher.
CENTRAL CORE LAYOUTS
SI NGLE-LOADED CORRI DOR LAYOUT
DOUBLE-LOADED CORRI DOR LAYOUT
TYPI CAL SECTI ON
Multi-family housing in high-rise buildings typically has acentral core with elevators, stairs and other buiding services.
The single loaded corridor, or gallery, is generally used to maximize bestview potential, for narrow lots, or to back-up to other buildings or uses.
The double-loaded corridor is the most efficient form of circulation inmulti-family housing. It can be used for low-, mid-, or high-rise buildings.
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Precast concrete plank, with the ability to free spanover 50 feet, can greatly reduce a buildings floor-to-floor height over other structural systems suchas steel frame. The result is a reduction in theoverall building height and the elimination of excessbuilding material and cost.
Typical Section
Typical Row House
Typica l Mul t i -Fam i ly Uni t Layout s
Unit layouts are typically dependent on the overall
building layout. Buildings with long corridorsnormally have units with the main living areas andbedrooms having direct access to outside light, thusrequiring these rooms to be along an exterior wall.
Service areas such as the kitchen, bathrooms,laundry and closets that do not require exterior lightare normally placed along the interior corridor wall.
STUDI O 1 BR 2 BR 3 BR
BALCONYBAY PROJECTI ON
BASEMENT 1 ST LEVEL 2 ND LEVEL 3 RD LEVEL
Row houses and townhouses areideal building types for theOldcastle Residential BuildingSystem. Each unit can becompartmentalized with sound
deadening precast concrete panelsand, with the use of precast plank,the floor layouts are virtuallylimitless. By enclosing the frontand rear with precast panels theend result is a quiet, energysaving, environmentally friendlyresidence that requires little or nomaintenance.
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RESIDENCE HALLS
The Oldcastle Residential Building System provides safe,secure, energy efficient, and low maintenance ResidenceHal ls and D or m i t o r i es for colleges and universities.
Fitting within the architectural character of campuses isgenerally a crucial factor in the design of residence halls.Often the need is for buildings with specific styles andmaterials. Oldcastles system of precast componentsincludes variations on materials such as brick and otherfacings to complement the most demanding conditions.
At the same time, the style of living units has evolved inrecent years to more than the single or double occupancyrooms with common shower areas. The diverse nature ofstudent populations places demands on colleges anduniversities to respond with appropriate housing types.
Dorm i to r ies , Su i tes , Stud ios , Apar t men ts , Coup les ,and F a c u l t y housing types each have differentcharacteristics; and an increasing number of institutionsare providing them to attract the best students and faculty.
This section of the manual illustrates various types ofbuilding and living unit configurations, leaving only theimaginations of the architect and owner to explore ideasto suit their specific requirements.
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SUI TES I NDOUBLE LOADED CORRI DOR
Common floor plan arrangements for collegeresidence halls often include centralized corefunctions with stairs, elevator, common parlor,bathrooms and showers as well as conferencerooms, study areas, kitchenettes and dining areas.
Living units range from single or double occupancyrooms to suites and apartment layouts along acentral corridor.
Corridor and living unit walls made of concretepanels can be provided with a smooth form finishand a trowel finish, ready for painting; thiseliminates the need for some interior drywallpartitions, greatly reduc ing r oom dam age andm a i n t enanc e issues.
RESI DENCE HA LLBUI LDI NG LAYOUTS
CENTRAL CORE W I THDOUBLE-LOADED CORRI DOR
CENTRAL CORE CORNER CORE
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The types of living arrangements in residence hallsvary depending upon the philosophy of collegeadministrators. Modern trends are for single anddouble-occupancy rooms for undergraduatestudents, while suites and apartment style unitsappeal to older undergraduate and graduatestudents seeking to live with a specific group ofpeople in a more normal residential environment.
Housing for younger undergraduates usuallyconsists of single or double occupancy sleepingrooms arranged along a common corridor andsharing common toilet and bathrooms.
Suite housing combines multiple single or doubleoccupancy sleeping rooms, typically two to six, witha shared living area and bathrooms. Suites areself-contained private living areas, and like standardundergraduate housing, do not have kitchens.
Apartment style housing is similar to suite housingwith the addition of a kitchen and possibly privatebathrooms.
DOUBLE OCCUPAN CY ROOMS
I N SUI TE STYLE LAYOUT
RESI DENCE HA LLUNI T LAYOUTS
SI NGLEOCCUPANCY
DOUBLEOCCUPANCY
DOUBLEOCCUPANCY
DOUBLE OCCUPAN CY ROOMSI N APARTMENT STYLE LAYOUT
SI NGLE OCCUPAN CY ROOMSI N APARTMENT STYLE LAYOUT
SI NGLE AND DOUBLE OCCUPANCY ROOMS
I N APARTMENT STYLE LAYOUT
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SENIOR RESIDENCES
The baby-boom generation of over-65 seniors is the mostrapidly growing population segment in the United States.The housing industry, in both the private and public sectors,is faced with the challenge of meeting the housing andcare needs of this highly diverse group of society.
The Oldcastle Residential Building System is capable ofproviding housing and service needs to the widest rangeof Sen i o r R esi denc e Bu i l d i ng T y pes, including thefollowing:
I ndependen t R esi den t i a l Apa r t m en t sGenerally for the active over-55 age population, this ishousing for people with limited care needs.
Cont in u ing Care Ret i rem ent Com mu ni t iesCCRCs are a model of living that provides services andcare for a wide variety of needs ranging from independentliving to more focused and specialized health care needsof assisted living and long-term care residents.
Ass is ted L iv ing Res idenceHousing for individuals unable to live on their own but notneeding the high level of care required in a long-termcare residence.
Long Term Care Res idenceFacilities for residents needing a high degree of servicesand care such as Alzheimers Care, Hospice Care,
Rehabilitation and Nursing Homes.
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SENI OR RESI DENCEBUI LDI NG LAYOUTS
Building layouts of senior residences vary dependingon a multitude of factors site size andconfiguration, lifestyle and program requirements,and owner and architect preferences. Some
common layouts are shown here.
There are many lifestyle options available forseniors. They can range from independent livingto assisted living and continuing care communities.
Each one is programmed and designed by ownersand architects to meet the lifestyle and health carerequirement of the residents.
I ndependent L iv ing Res idences provide a placefor seniors to live within a community of others theirage, with little to no health care support.
As s i s t ed L i v i ng R es i denc es provide varyingsupport services based on the changing needs ofthe residents. Typically they are for those who are
unable to live safely on their own, but who do notrequire a high level of health care support.
Cont inu ing Care Ret i rement Comm uni t ies offerhousing for seniors requiring a full compliment ofsupport services such as dining, housekeeping,health care, and access to social activities.
DOUBLE-LOADED CORRI DORDOUBLE WI NGS
CENTRAL COURTYARD
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MULTI -BEDROOM SUI TE
2 BR APARTMENT
SMALL 1 BRSTUDI OSLEEPER
SENI OR RESI DENCEUNI T LAYOUTS
2 BR SUI TE
LARGE 1 BR APARTMENT
Developers of senior living facilities, and theirarchitects, create programs and designs to suitspecific market targets. The design of eachindividual living unit is at the heart of their decision-making process.
Senior residence living unit designs vary greatlydepending on the health, well-being and lifestyleof the individuals. Seniors still living active,
independent lifestyles generally seek the type ofliving arrangement that reflects their independence full kitchens, large furnishable living rooms andbedrooms, and adequate storage. On the otherhand, some seniors, particularly those with lifechanging conditions such as dementia orAlzheimers, may be better served with smallerunits, or shared suite arrangements, that arecomplemented with an array of beneficial servicesand activities in the building.
This page shows several of the plan layouts for livingunits that are commonly used in senior residences.Often the development, particularly in ContinuingCare Retirement Communities and Assisted LivingFacilities, will have a wide mix of living unitarrangements to suit the needs of a diverse seniorpopulation.
Reaching an understanding of the living unit mixand design requirements in a project helps
considerably in the planning and design of thebuilding layout and characteristics of the appropriatesuperstructure. Oldcastle representatives can assistowners and architects in the early programmingand planning phases of the project to identify cost
effective solutions for each condition.
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MIXED-USE
Owners and architects are often faced with the challengeof providing more than one use in a development, often ina single building.
Where a mix of different uses is required in the building, itis important at the outset of design to gain anunderstanding of a design module that can suit each use.For example, the module of a parking garage - the carand the space it needs - is different for multi-familyhousing, hotel rooms and conference areas, professionaloffices, and retail space. Nevertheless, all of these different
uses could be combined into a single building.
The Oldcastle Residential Building System is specificallydesigned to create superstructure solutions thataccommodate varying conditions. It is important for theOldcastle representative to gain a clear understanding ofthe program and design parameters early in the processto maximize the potential for cost-effective solutions for
both the superstructure and building envelope.
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OLDCASTLE RESIDENTIALBUILDING SYSTEM
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BS.1 Architectural Principles ofConcrete Design
BS.2 Precast System ComponentsBS.3 Cross Wall SystemBS.4 Bearing Wall SystemBS.5 Wall PanelsBS.7 Floor and Roof PlankBS.8 Balconies
BS.9 StairsBS.10 ElevatorsBS.11 Facade Treatment OptionsBS.13 Concrete FinishesBS.14 Formliner FinishesBS.15 Embedded BrickBS.18 Brick FinishesBS.19 Other Trim Materials
OLDCASTLE
RESIDENTIAL
BUILDING SYSTEM
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EXTERI OR I NSULATED ANDNON-I NSULATED LOAD BEARI NG PANELS
BEAMS
OLDCASTLE PRECASTSYSTEM COMPONENTS
COLUMNS
STAI RS AND
LANDI NGS
FORM LI NER
FINI SHES
REAL BRI CKFACI NG
DECORATI VECORNI CES
BALCONYSLABS
FLOOR ANDROOF PLANKS EXTERI OR NON-LOAD BEARI NG PANELS
I NTERIOR LOAD BEARI NGPANELS AND SHAFTS
I NTERI OR NON-LOADBEARING PARTI TI ONSAND SHAFTS
Oldcastle provides total precast concrete solutions forresidential buildings. From exterior walls with architecturalfinishes, to floor and roof structures, stairs and shafts,and the entire superstructure, the Oldcastle System ofcomponents is designed to accommodate the wide range
of residential building types and uses illustrated in thismanual.
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CROSS WALL SYSTEM
SECTI ON
The Oldcastle Residential Cross Wall System is comprisedof load-bearing interior precast panels and floor and roofplanks. Columns and beams are used at parking levels.Non-load bearing exterior panels can enclose thesuperstructure, providing a total precast concrete buildingsystem.
Cross Wal l Advantages:
Ideally suited for residential
buildings with parking at lowerlevels
Lends itself well to the addition
of bays and balconies Allows for a high percentage
of non-load bearing exteriorpartitions
Creates the opportunity for
sound-deadening precast wallsbetween units
ROOF PLANK
NON-LOAD BEARI NGEXTERI OR WA LL
BALCONY SLAB
LOAD BEARI NGCROSS WALL
BEAMS &COLUMNS
BEAMS &COLUMNS
FLOOR PLANK
LOAD BEARI NGCROSS WALL
NON-LOAD BEARI NGEXTERI OR WALL
ROOF PLANK
FLOOR PLANK
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SECTI ON
The Oldcastle Residential Bearing Wall System is comprisedof load bearing interior and exterior precast panels withfloor and roof plank, providing a total precast concretebuilding system.
Bear ing Wal l Advantages :
Maximizes the open areas of
building plans
Creates flexible options for
floor plan layouts
Creates a sound-deadeningprecast wall at the corridor
Least expensive total precast
solution
Building is enclosed as
structure is being erected
BEARI NG W ALL SYSTEM
FLOOR PLANK
LOAD BEARI NGEXTERI OR WALL
LOAD BEARI NGI NTERIOR WALL
ROOF PLANK
LOAD BEARI NGEXTERI OR WALL
ROOF PLANK
FLOOR PLANK
LOAD BEARI NGI NTERIOR WALL
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12 MAX
40MAX
40 MAX
12MAX
W ALL PANELS
STANDARD PANEL I NSULATED PANEL
SPECI AL SHAPESVERTI CAL
HORI ZONTAL
Within the Oldcastle system of components, precast wallpanels are available in a wide variety of types,configurations and finishes. From interior load-bearingstructural panels to exterior, insulated, brick-embeddedarchitectural finish panels, the Oldcastle system is designedfor total precast solutions for residential buildings.
Typically, precast panels are cast on flat forming beds withincontrolled factory conditions. Depending on the desiredarchitectural effect, various formliner finishes or masonryfacing options are available.
Window and door openings are created by blockouts onthe forming bed, and rails are placed to form the panelperimeter. After reinforcement and lifting devices areplaced, the concrete is poured and cured. The panels are
then lifted by cranes and stored until delivery and erectionat the job site.
Standard wall panels are 6 to8-inches thick, depending onuse and function. Non-loadbearing conditions typicallyrequire no more than 6-inches, whereas load-bearingconditions usually require 8-inches.
Insulated wall panels consistof three wythes; a 2-3 inchconcrete exterior, 2-3 inchesof rigid insulation, and 2-8inch concrete interior.Insulated wall panels can beused in both non-load bearingand load-bearing conditions.
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BALCONI ES
Oldcastle offers a variety of solutions for precastconcrete balconies and bays in both cantileveredand recessed applications. Wet cast slabs are thepreferred method, enabling proper pitch and drain-age. Consult with Oldcastle engineers for appro-
priate designs.
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STAI RS
CODE CONSI DERATI ONSBeing an essential component in the circulation andegress systems of most buildings, stairway designis strictly controlled by building code regulations.The information contained here summarizes somecommon building code requirements for egresss t a i r w ay s. However, designers must always verifywith the latest national and local codes.
St a i r w ay W i d t h the minimum stairway widthshall not be less than 48 wide for enclosed exitstairways.
Risers and Treads - shall be of uniform size andshape. Risers shall be between 7 max. and 4 min.The tread depth shall be 11 min. The mostcommon rule for comfortable proportioning of stairsis: 2 x riser height + tread depth = 25 inches.
Land ings the width of landings shall not be less
than the width of the stairway they serve and arerequired at the top and bottom of stairs andintermediate points to ensure that no single flightof stairs has a rise greater than 12-0.
Handra i l s are required on both sides of stairsand may project into the required stairway widthno more than 4-1/2 on each side. They shall beuniform in height, located 34-38 above the stairtread nosing. Handrails must be continuous or theends must project beyond the top and bottom ofthe stairs and return to a wall or guard.
G u a r d r a i l s shall be no less than 42 high,measured vertically from the leading edge of treadand shall have balusters or ornamental patterns sothat a 4-inch diameter sphere can not pass through.
Roof Access buildings over four stories with aroof slope less than 4 in 12 require stair access tothe roof.
Stairway walls, floors, landings and steps are allprecast concrete components that can be providedas part of the Oldcastle Residential Building System.
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ELEVATORS
ELEVATOR PLAN
The elevator system, consisting of the hoistway, machine
room, cab and lobbies, is an integral and complex system.Proper sizing, quantity and type of elevator depends onthe number of occupants, number of floors, floor heightsand other factors.
Oldcastle Precast has a complete line of concrete productsto meet the requirements of the elevator hoistway andpenthouse to complement and support the OldcastleResidential Building System.
An elevator representative and code official should beconsulted early in the design phase and during the selectionprocess to ensure that the most suitable elevator systemis chosen.
The two most common elevator systems are Hydraulicand Electric elevators.
Hydrau l i c E leva to rs
Hydraulic elevator systems come in two styles, holed and
holeless. Both use a pump near the base of the hoistwayto raise and lower the elevator cab using a plunger. Dueto restrictions in the plunger length and lower speeds,hydraulic elevators are limited to low- and mid-risebuildings of up to approximately 60 feet. They generallyrequire the least initial installation cost, but use more powerduring operation.
Elect r ic Elevators
Electrical elevators rely on an electric motor and drivesheave that raises and lowers the elevator cab by steelcables and a counterweight. The electric motor is locatedeither at the base or above the hoistway. Medium to highspeeds and almost limitless rise allow electric elevators toserve low- to mid- to high-rise buildings.
ELEVATOR SECTI ON
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SAMPLE CONCRETE FI NI SHES
Oldcastle Precast offers a wide range of
precast concrete colors and textures. Thearchitect should contact the local Oldcastlerepresentative in the early design stages andthroughout the development of the design forinformation on how to best obtain the visualeffect desired.
Note:The images shown in this manual representmany of the available color and texture
blends. These samples serve only as a visualguide for initial selection of color and texture.It is important to note that the colors andtextures seen will vary depending on localconditions. Since it is impossible to reproduceexactly on paper the true colors of precastmix designs, some variations from thesesamples must be expected.
Additionally, due to different material sourcesor different techniques in various plants, the
architect should not expect to select aphotographic sample and obtain exactmatching by all precast concrete producers.Samples should be required to ensure thatthe desired colors and textures can besatisfactorily matched.
Photos courtesy of PCI
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08070605
09 10 11 12
13 14 15 16 17 18
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SAMPLE FORMLI NER FI NI SHES
Forml ine rs
Oldcastle offers owners and architects theoption to cast concrete in forms with specialtyformliners to create almost any desired visualeffect. In addition to a vast array of patternsand textures offered as standard, there is alsothe option to create custom formliner finishesin almost any style imaginable. Oldcastleworks directly with the nations premiermanufacturers of formliners including those
represented in the patterns shown on thesepages.
The images shown in this manual representmany of the textures and patterns available.The samples shown are only a visual guide forinitial concept, not for actual selection. TheOldcastle representative will make availablemore accurate literature and samples when
requested.
Mason r y St on e an d RockLow Pro f i l e
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EMBEDDED BRI CK
COURSI NG OPTI ONS
CORE SAMPLE SHAPES AND SI ZES
FLEMI SH BOND HALF BOND STACKED BOND
BASKET W EAVE QUARTER BOND ROW LOCK BOND SOLDI ER BOND
RUNNI NG BOND
NO MORTAR
NO AI R SPACE
NO WEEP JOI NTS
NO LI NTELS
NO FLASHI NG
NO WATERPROOFI NG
NO EFFLORESCENCE
NO FREEZE/ THAW
NO DOVETAI L
ANCHORS
1
2
4
3
For owners and architects seeking brick finishes,Oldcastle offers thin brick which is integrally castinto concrete panels. A wide variety of sizes,shapes, colors and textures are offered, as well asa multitude of coursing options. Advantages of
brick-embedded concrete include no flashing, lintelsor weep cavities, no efflorescence and no time-consuming site construction or masonry products.
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EMBEDDED BRI CK OPENI NGS
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BRI CK AND CONCRETE FRAMESBRI CK FRAME
For an all-brick facade appearance, brick returnscan be applied at jambs, sills and heads. Carefulplanning of window sizes is required if minimizingthe cutting of bricks is a goal. At sills, a sloping sillextender is required from the window manufacturerto fully cover any flat brick surface.
TYPI CAL OPENI NG DETAI LS
CONCRETE FRAME
For the traditional appearance of stone sills andheads, concrete can be formed either flush with orprotruding from the brick facade. Brick returns aretypically applied at the jambs.
The most cost-effective opening is formed withconcrete at the jambs, sill and head. This reducesthe amount of brick cutting and allows for flexibilityof window sizes as the openings are determined bythe concrete, not brick coursing. The concrete framecan be flush with the facade or protruding.
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flush or protruding flush or protruding flush or protruding
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SAMPLE BRI CK FI NI SHES
Thin Br ick
Oldcastle offers owners and architects theoption to integrally cast brick in concrete. Fromthe nations premier manufacturers of thinbrick, there is a wide array of brick optionsavailable. The images shown in this manualrepresent many of the available color andtexture blends. Brick corners and edge capsare also available. Furthermore, flashed blendssuch as light, dark, and vintage flash and mixed
blends are available by custom order inminimum quantity orders.
Advantages of brick-embedded concreteinclude no flashing, lintels or weep cavities;no efflorescence; and reduced constructiontime.
Thin brick may vary in size and shade fromrun to run and within each run. Bricks shouldbe blended from numerous cartons on the jobsite. The color samples shown here are only a
visual guide for initial concept, not for actualselection. The Oldcastle representative willmake available more accurate color literatureand samples when requested.
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OTHER TRI M MATERI ALS
Oldcastle assists designers and owners in the coordinationand design of its precast products with various exteriortrim materials such as composites, metal, wood, terracotta, ceramics, masonry, EIFS, and fiberglass.
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ARCHITECTURAL &
STRUCTURAL DETAILS
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USE OF THESE DETAI LS
The drawings and other information contained herein are illus-trative only and neither Equus Design Group, Inc. nor OldcastlePrecast, Inc. makes any representations as to their fitness forany specific design or structure, and disclaim any responsibilityfor techniques of application, correctness, interpretations, de-sign methods, modifications or misapplications of these drawingsand references.
Since no specific project nor overall engineering responsibility isimplied with the use of this manual and the information con-tained within, neither Equus Design Group, Inc. nor OldcastlePrecast, Inc. will be responsible for the failure of any designer toproperly design nor any contractor to properly construct anybuilding.
ARCHITECTURAL DETAILS
INSULATED LOAD-BEARING PANEL DETAIL2
NON-INSULATED PANEL-TO-FOUNDATION DETAIL4
BELOW-GRADE PARKING FOUNDATION DETAIL3
NON-INSULATED LOAD-BEARING PANEL DETAIL1
INSULATED PANEL-TO-FOUNDATION DETAIL5
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ARCHITECTURAL DETAILS
PRECAST PARAPET DETAIL2
TYPICAL COPING DETAIL AT ROOF4
INTERIOR PANEL-TO-PANEL DETAIL3TYPICAL COPING DETAIL AT PARAPET1
INSULATED PANEL WITH PARAPET DETAIL5 INTERIOR PANEL-TO-FOUNDATION DETAIL6
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ARCHITECTURAL DETAILS
BUTT CORNER JOINT DETAIL2
PRECAST CONCRETE BEAM SECTION4
BRICK CORNER JOINT DETAIL3MITERED CORNER JOINT DETAIL1
WINDOW SILL DETAIL - NON-INSULATED PANEL5 WINDOW SILL DETAIL - INSULATED PANEL6
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STRUCTURAL DETAILS
USE OF THESE DETAI LS
These details represent a sampling of typical Oldcastle BuildingSystem details for various building conditions. Please consultan Oldcastle representative for specific details for each project.
The drawings and other information contained herein are illus-trative only and neither Equus Design Group, Inc. nor OldcastlePrecast, Inc. makes any representations as to their fitness forany specific design or structure, and disclaim any responsibilityfor techniques of application, correctness, interpretations, de-sign methods, modifications or misapplications of these draw-ings and references.
Since no specific project nor overall engineering responsibility isimplied with the use of this manual and the information con-tained within, neither Equus Design Group, Inc. nor OldcastlePrecast, Inc. will be responsible for the failure of any designer toproperly design nor any contractor to properly construct anybuilding.
EXTERIOR WALL AT FOUNDATION5
PLANK SIDE CONNECTION AT EXTERIOR WALL3PLANK END BEARING AT
EXTERIOR INSULATED WALL1 PLANK END BEARING AT EXTERIOR WALL2
EXTERIOR INSULATED WALL
AT FOUNDATION
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STRUCTURAL DETAILS
INTERIOR WALL AT FOOTING5PRECAST COLUMN AT FOOTING4
PRECAST CONCRETE BEAM SECTION1
PLANK BEARING AND SECTION AT
CORRIDORS AND LARGE OPENINGS6
PLANK END BEARING AT INTERIOR WALL2 PLANK END BEARING AT EXPANSION JOINT3
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STRUCTURAL DETAILS
INTERIOR WALL PANEL JOINT6
ROOF PLANK BEARING AT EXTERIOR WALL1
( PLAN VI EW) ( PLAN VI EW)
( PLAN VI EW) ( PLAN VI EW)
ROOF PLANK BEARING AT INTERIOR WALL4
INSIDE WELD PLATE CONNECTION
AT CORNER WALL PANELS2 OUTSIDE WELD PLATE CONNECTION
AT CORNER WALL PANELS3
WALL PANEL BUTT JOINT
WITH HIDDEN CONNECTION5
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SUSTAINABLE DESIGN
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CASE STUDIES
CASE STUDIES
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The Juliana Lincoln University
Melrose II University of Delaware4Scranton University
THE JULIANA
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Hoboken, New Jersey
Pro jec t Descr ip t i on - 128-unit luxury livingcomplex comprised of two four-story buildings withcovered first level parking, bay window projectionsand courtyard, totaling over 201,000 SF.
II. Pro ject Team -Owner:
Kawoz LLC, Hoboken, NJGeneral Contractor:
Ashley REMI Inc., Hoboken, NJArchitects:
Equus Design Group, Inc, Belmont, MA(precast concrete design architects)Bodnar Architects & Assoc. Long Valley, NJ(local architect-of-record)
Precaster and Precast Specialty Engineers:Oldcastle Precast Building Systems Division
III.
I.
Majo r Fea tu res -Total Precast Building System:
Exterior Load and Non-Load Bearing Panels
Interior Load Bearing Cross Wall Panels
Hollow Core Floor and Roof Planks
Special Bay Window Floor Projection Slabs
Beams and Columns at Parking Level
Stairs and Landings - Interior and Exterior
Elevator and Stair Shaft Walls
Special Arch, Pediment, and Curved Panels
Embedded Brick Finish (9 colors)Formliner Finish (stone)Composite Cornice and Trim1,624 Precast Pieces
696 8-foot wide planks72 columns40 beams244 7- and 8-inch interior wall panels48 stairs48 landings408 exterior wall panels
THE JULI ANA
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Three levels of living units above oneenclosed garage in two separatebuildings
Exterior wall panel being poured inthe plant
Metal clad bay window projectionsin rhythm with embedded thin brickprecast panels
Precast panels and stairs used tocreate 2nd level entries
Exterior wall panel being erected atthe 2nd level
Exterior facade with compositewindow header and cornice, andmetal clad bay window
Concrete floor projections at baywindows
Acid etched precast panels withstone-like formliner finish at base ofbuilding
View from street showing stair to liv-ing units, bay projections, thin brick
and composite headers over precastframed window openings
End view of both buildings at sidestreet 1st level garage entries
Courtyard view between both build-ings showing a variety of different
thin brick colors
Ornamental bracketed compositecornices atop the precast panels
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ORIGI NAL FLOOR LAYOUT ( TYPI CAL)
MODI FI ED FLOOR LAYOUT ( TYPI CAL)
PRECAST FLOOR LAYOUT ( TYPI CAL)
The original design of the Juliana project was load bearing metal stud construction witha brick exterior cavity wall and concrete floor and roof plank.
Oldcastle was able to implement the total precast Cross Wall Building System with onlyslight modifications to the unit arrangement and minimal changes to unit layouts, unitcounts, and exterior appearance, greatly simplifying the structural system of the project.
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Precast floor plank span and bear on the interior precast cross walls and end walls ofthe building. A steel lintel is used between the cross walls at the corridor location.
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PARTI AL MODI FI ED FLOOR LAYOUT
PARTI AL PARKI NG GARAGE LAYOUT
Parking layouts are easily adaptable to the Oldcastle Cross Wall Building System. With theuse of columns and beams to carry the load of the Cross Walls above, and the Drop-Beam
sytem for running utilities, there is ample space to provide safe and secure parking on thefirst level, protected from the weather.
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ORI GI NAL FRONT ELEVATI ON
MODI FI ED FRONT ELEVATI ON TO A CCOMODATE PRECAST
PRECAST FRONT ELEVATI ON
The modified front elevation designed with precast concrete panels. With minor changesOldcastle was able to maintain the original design of the facade using precast concretepanels. This example shows the compatibility of precast concrete components and howthey can be used in place of common building products and still achieve the same design.
The modified front elevation showing only the exterior concrete panel components.
The original front elevation designed with a brick cavity wall.
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LINCOLN UNIVERSITYLINCOLN UNIVERSITY PENNSYLVANIA
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LINCOLN UNIVERSITY, PENNSYLVANIA
Pro jec t Descr ip t i on - Two phase, fourstory 120,000 SF residence hall. The precaststructure was erected during the middle of winter.
II. Pro ject Team -Owner:
Lincoln UniversityGeneral Contractor:
EDIS Company, Wilmington, DE
Architects:AP3C Architects, Philadelphia, PA
Precaster:Oldcastle Precast Building Systems Division
III.
I.
Majo r Fea tu res -Total Precast Framing System:
Cross Wall System
7-inch Load Bearing Interior Panels
Hollow Core Floor and Roof Planks
Stairs and Landings
Elevator and Stair Shaft Walls
LI NCOLN UNI VERSI TY
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Grouting the base of an interior pre-cast wall panel
Interior precast stairs and landing Inter ior precast wall panels andplank along unfinished corridor
Infilling the shoring/bracing anchorsto provide a smooth wall ready forpainting
Setting a precast concrete floor plank Shoring of interior precast wall pan-els while floor plank is set andgrouted
Columns and beams at corner studyarea
Stairwell enclosure at end of build-ing
Winter erection of precast panels andplank
Exterior brick facade Completed Phase 1 on the right withPhase 2 panel erection on the left
Finished exterior building facade
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TYPI CAL UPPER FLOOR LAYOUT
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PARTI AL UPPER LEVEL FLOOR PLAN
PARTI AL STRUCTURAL FLOOR PLAN
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PARTI AL FLOOR PLAN
ENLARGED TYPI CAL SUI TE PLAN
MELROSE COMMONS IIBronx, New York
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Pro jec t Descr ip t i on - Affordable ownershipand rental housing comprised of 30 three-storytownhouse units with courtyard and off-street park-ing.
II. Pro ject Team -Developer:
MC II LLC, New York, NYBuilder:
Blue Sea Construction LLC, New York, NY
Architects:Equus Design Group, Inc, Belmont, MA(precast concrete design architects)Danois Architects. New York, NY(local architect-of-record)
Precaster and Precast Specialty Engineers:Oldcastle Precast Building Systems Division
III.
I.
Majo r Fea tu res -Total Precast Building System:
Exterior Load and Non-Load Bearing Panels Interior Load Bearing Wall Panels
Hollow Core Floor and Roof Planks
Special Window Head and Sill Projections
Special Three-Sided Stairwell Channels
Exterior Stairs and Landings
Cornices
Embedded Brick FinishFormliner Finish (stone)Over 2,400 concrete pieces
Aw ards Rece ived - First affordable housing development in New
York State to receive Energy Star certifica-tions
National Association of Home Builders (NAHB)
HUD Secretarys Platinum award
NESEA Northeast Green Building first place
residential award
BSHF World Habitat Innovative Housing
database listing NAHB Energy Value Housing Silver Award
IV.
MELROSE COMM ONS I I
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Pouring concrete panel with selfcompacting concrete over thin brickveneer
Power washing panel prior toshipping to job site
Exterior wall panel on truck readyto be shipped to job site
Non-load bearing front wall panelbeing erected
Precast entry channels and cornicesEndwall panel with embedded thinbrick veneer, water table and stoneformliner
Concrete channel being lifted intoposition
Initial pre-construction rendering
Precast cornice, entry channel andfront wall panel
Precast concrete projecting windowheader with concrete window jambs
Completed Melrose Commons IIaffordable housing
HUD Secretarys Platinum Awardfrom the National Association ofHome Builders (NAHB)
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PARTI AL ELEVATI ONFLOOR PLAN LA YOUTS
SI TE PLAN STRUCTURAL PLANK LAYOUT
BASEMENT 1ST LEVEL 2ND LEVEL 3RD LEVEL
Mel rose Com m ons I I - Floor and roof planks spanned be-tween interior load bearing panels and exterior end unit walls. Non-
load bearing front wall panels and three-sided precast channel piecesenclosed the front of the housing units. Precast stairs and landingswere used between levels. A decorative precast concrete cornice com-pletes the facade.
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CONDRON HALLUniversity of Scranton
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University of ScrantonScranton, Pennsylvania
Pro jec t Descr ip t i on - Seven-story, 386-bedtotal precast concrete residence hall that containsover 108,000 sf of living space, erected in only four-teen weeks.
II. Pro ject Team -Owner:
University of ScrantonArchitects:
Equus Design Group, Inc, Belmont, MA(precast concrete design architects)Burkavage Design Associates, New York, NY(local architect-of-record)
Precaster and Precast Specialty Engineers:Oldcastle Precast Building Systems Division
III.
I.
Majo r Fea tu res -
Total Precast Building System: Exterior Load and Non-Load Bearing Panels
Interior Load Bearing Wall Panels
Hollow Core Floor and Roof Planks
Window Head and Sill Projections
Interior Stairs and Landings
CornicesEmbedded Thin Brick FinishConcrete Formliner FinishFormliner University Seal and Name
Over 500 concrete wall piecesOver 100,000 sf concrete plank
CONDRON HALL
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Custom formliners were used tocreate embossed precast buildingname and University seal
Embedded thin brick in differentcolors and coursing patterns
Stairwell, dorm rooms and commonareas all clad with precast panels
Wide, unobstructed clear spansmade possible with precast spandrelpanels
Thin brick being layed in formlinerprior to pouring of concrete wallpanel
A combination of mitered and buttjoints used to create visual continu-ity
Exterior wall panel on truck readyfor shipment to job site
Projected concrete window framedopenings
Precast panels used to createprojections and recesses of themodulating facade
Precast concrete walls used for bothexterior and interior applications
A combination of formliner finish andembedded thin brick precast panelsused to create architectural interest
Building as seen from distant high-way entrance
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TYPI CAL FLOOR PLAN LAYOUT STRUCTURAL LAYOUT
Condr on Hal l - Using a bearing wall System, floor and roof plankspan between interior and exterior load bearing panels. Load bearingendwall and stairwell panels are also used to enclose the ends of thestructure. Precast stairs and landings are used between levels.
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University of DelawareNEWARK, DELAWARE
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Pro j ect Descr ip t ion - This project, built in1971, is the first total precast high-rise studenthousing built in the United States. The two 17-story dormitories were designed to accommodate1,300 students. The towers have 375,000 SF andincorporate 255 one-bedroom apartment units and197 two-bedroom units.
II. Project Team -Owner:
University of DelawareGeneral Contractor:
Ogden Development GroupJoint Venture with Frederic G. Krapf & Sons,Inc., Wilmington, DE
Architects:Charles Luckman Associates, New York, NY
III.
I.
Major Features -Total Precast Framing System:
Cross Wall System
Insulated Load Bearing Exterior Panels
Load Bearing Interior Panels
Prestressed Hollow Core Floor and Roof Planks
Precast Columns, Beams and Stairs
Elevator and Stair Shaft Walls
Fluted FormlinerOver 5,000 Precast Concrete Components
UNI VERSI TY OF DELAW ARE
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A total precast student dormitory The structure was erected at a rateof one floor per week per building
Eight-foot wide hollow core concretefloor and roof planks
Erection of a total precast buildingsystem
Wide corridors are made possiblewith steel headers for floor plank
Exterior wall panels contain foaminsulation cores which provide highthermal resistance
Combined precast stair and landings The exterior concrete panels werefinished with a light sandblast
17-story high-rise dormitory A storefront wall system is installedbetween concrete panels
The fluted formliner finish is outlinedby smooth spandrels and corners
Both high-rise towers as seen fromthe university campus
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TYPI CAL FLOOR PLAN
TYPI CAL TW O BEDROOM APARTMENT PLAN
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REFERENCES & RESOURCES
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