precastconcretepanels_techspec

7/29/2019 precastconcretepanels_techspec

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1TECH SPECS >

Precast Concrete Panels

YOUR BLUEPRINT FOR USING ADVANCED BUILDING TECHNOLOGY

DOLLARS & SENSE

Costs for materials and labor

to install precast concrete

panels Page 2

MAKING THE SWITCH

What it takes to switch from

masonry foundations to

precast panels Page 2

RESULTS FROM THE FIELD

Field evaluation results from

Maryland and Delaware...

Page 2

FOOD FOR THOUGHT

What to consider to be sure

precast panels are right for

your project Page 3

TECH CHECK

Steps you need to take if you

decide to start using this

building technology Page

PrecastConcret

Panels

BENEFITS (+) / DRAWBACKS (-)+AFFORDABILITY: Reduced labor costs due to

quicker/easier assembly, in some cases nomason is required

+ QUALITY/DURABILITY: Tornado/hurricanedamage resistance; fire, termite, and dry-rotresistance

+ ENERGY EFFICIENCY: Requires lessinsulation

+ MARKETABILITY: Low maintenance andimproved sound-proofing

+ SCHEDULING: Panels cure in the factory, andcan be erected in cold temperatures,preventing concrete pour delays

AFFORDABILITY: Higher up-front cost;requires on-site crane; may require certifiedinstaller

INITIAL COSTPrecast concrete systems generally cost between$55 and $65 per linear foot of wall, making themcompetitive with other foundation walls. Rapidassembly and erection can significantly reducelabor costs. For most projects, a concrete footingis not required, which can reduce on-site materialand labor costs. However, panel erection requiresa crane which will have added cost, but that costmay be offset by labor and t ime savings.

OPERATIONAL COSTAn insulated precast concrete system can reduceenergy bills throughout its expected life.

CODE ACCEPTANCESections R401 through R406 of the 2003International Residential Code outlinerequirements for foundations including materials,footings, foundation walls drainage, andwaterproofing. According to section R 402.3,precast panels must be designed and installed

according to the provisions of the code and themanufacturers installation instructions.

RESULTS FROM THE FIELDField evaluations have demonstrated thatprecast concrete foundations can be installedquickly and easily, and can offer significant laborsavings.

WARRANTYWarranties vary by manufacturer.

MAKING THE SWITCHPrecast concrete panels are prefabricated in afactory, and are easier to assemble on site thanpoured concrete or masonry. Erection time isgreatly reduced. Connections, bracing,reinforcement, and openings need to bedesigned and detailed before fabrication.

TECH @ A GLANCE THE BASICS

Precast concrete foundation walls arepanels that are cast and cured in acontrolled factory environment, whichhelps ensure panel quality and uniformit

Panels can be installed in a fraction of thtime that poured concrete foundations atraditional exterior walls would take. Whpanels are delivered to the site, they areoften erected in three or four hours.Because the concrete is cured in the

factory, foundations can be backfilled assoon as the slab and first-floor are braceThe factory fabrication process reduces eliminates weather delays.

Panels are cast as solid reinforced precaconcrete (flat panels), or as reinforcedconcrete ribbed panels with a thin exterishell. Some manufacturers cast theconcrete against foam insulation as a fowhich provides additional insulation (higR-value) for the structure. Concrete pancan be designed with a strength of 5,000psi. This results in panels that are strongthan concrete block or most poured

concrete walls, but are thinner and lighteweight. Walls may be customized duringthe order process to allow for door andwindow openings, steel beam pockets, abrick ledges.

Although precast concrete panels can binstalled rapidly, installers who are notfamiliar with prefabricated panel assembwill need additional training. In fact, sommanufacturers only allow certified installto deliver and erect their systems.


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DOLLARS AND SENSE

Precast concrete systems generally cost between $55 and $65 per linear foot of wall, making them competitive with other foundationwalls. Installation times can be extremely short. For the PATH MADE Home, the crushed stone bed took two hours to prepare, and thepanels were set in three hours.

Although precast concrete panels can be installed rapidly, installers who are not familiar with prefabricated panel assembly will needadditional training. In fact, some manufacturers only allow certified installers to deliver and erect their systems, which could addto the cost. Use of precast panels should be submitted for building code approval with the building permit application, which may be anadditional cost over conventional construction during the design phase.

MAKING THE SWITCHWhat is required to transition from yourcurrent building practices to using this

technology?

Check Local Codes Consult local codeprovisions affecting precast concretepanels.

Select a Precast System Considerlocation, delivery options, whether certifiedinstallers are required, and system optionswhen making the choice. Wall panels canbe produced in numerous colors andfinishes, which allow a broad range ofaesthetic options.

Review Home Designs Check standard

home plans for suitability for precastpanels. Remember, wall panels mustgenerally be customized to allow forwindow and door openings. Most wallpanels feature embedded connectionhardware so they can more easily beconnected into a complete framingassembly.

Train Installers - Installers must be trainedin precast concrete panel assembly. Somemanufacturers may require assembly bytheir own certified installers. Review themanufacturers guidelines for installation

and backfilling and prepare for anyadditional requirements outlined by localcodes, such as extra waterproofing.

Work With Your Trade Contractors Advise framers of connection details toframing, electricians and plumbers ofrouting considerations, masons of pouredflooring, and drywallers of any pre-attached firring strips.

Tools A crane is required for erection,along with wrenches to bolt connections.

RESULTS FROM THE FIELDThis technology has been used by other builders in real-world building situations learnfrom their experiences.

Bowie, Maryland, MADE Homes (PATH Field Evaluation) MADE (Marketable, Affordable, Durable, Entry-level) Homes Project recorded builder

experience constructing four 1,800 square foot detached single-family homes Two homes used precast concrete foundation panels by Superior Walls

Builder found panels to be cost-competitive withformed/poured concrete walls and blockfoundations; panel manufacturer used its owninstallers to construct the foundation

Precast panels are water-resistant and did notrequire additional waterproofing; however, localcodes required additional protection, which wasprovided with an acrylic spray-applied coating, inlieu of traditional asphalt based coatings

Preparation of 6-inch crushed stone base tookabout two hours; setting precast foundation wallstook less than three hours

First panel set in place and braced with 2x4s;second panel placed to form a corner

Panels were connected at the top and bottom with5/8-inch bolts, inserted through steel plates cast intothe wall at factory

After one corner was set, no further bracing was required

Dover, Delaware,Rolling Meadows Subdivision, Dunrite Construction, Inc. (PATHCase Study) Dunrite Construction, Inc. built 13 detached single-family homes in a 40-lot subdivisio For home designs with basements, builder found precast concrete foundation panels

were cost effective and faster to install than block foundations Superior Walls

precast foundation panels provided to Dunrite by Weaver Precast, Inc

of Ephrata, PA Panels were pre-manufactured in a variety of standard heights, and lengths up to 16 f

constructed using 2x8 fiber- and steel-reinforced concrete studs with polystyreneinsulation and 2-inch concrete shell

Structural design provided sufficient load-bearing capacity at less than 1/3 the weight typical 10-inch thick concrete wall, allowing panels to be placed on bed of gravel, raththan concrete footings

Manufacturer estimated most builders can save 15 percent over traditional basementfoundation construction


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FOOD FOR THOUGHT

This section provides some things to think about before switching to this buildingtechnology make sure its the right choice for you.

Although precast concrete panels offerspeedy installation, many manufacturersrequire panel assembly by their owncertified installers.

Panels require a crane for placement.

The stone sub-base must be compactedand leveled to provide an even surfacefor panel erection, and later floor joistinstallation.

Configurations may be customizedduring the order process to allow fordoor and window openings, steel beampockets, and brick ledges to be cast intothe panels. This requires additionalinitial effort during the planning stage.

Use of precast panels should be

submitted for building code approvalwith the building permit application.

For retrofits, significant excavation maynot be feasible in affected foundationwall areas with limited access.

Planning. The manufacturer will requiredetails about soil conditions, theexcavation and the structures design,and must receive approved drawingsbefore production can begin.

Code Acceptance. Designs that useprecast walls should be submitted forpre-approval with other architecturaldetails with the building permitapplication. Precast concretemanufacturers generally provideengineering and energy performancedocumentation to builders to facilitatetheir acceptance by local buildingdepartments

Arrange crane access. Makenecessary arrangements for a crane andcrane access to the site.

Prepare foundation base. The site isexcavated, and a six to 12-inch gravelbed is prepared over drain pipe, forbearing and drainage. Make sure thatgravel base is level to provide an evensurface for the floor joist installation. Noconventional poured footer is necessaryfor many residential applications.

Place and assemble panels.A cranis used for lifting and placing precastconcrete panels, which are then seaand bolted together. Apply awaterproofing material if required bycode or desired.

Pour slab and install floor systemOnce panels are assembled, pour thbasement slab. Floor joists areinstalled above the foundation toprovide bracing before backfillingfoundation walls.

Backfill. Once braced by the slab anfloor system, the foundation can be

backfilled. Manufacturers provideguidelines for bracing and backfilling

TECH CHECK

This checklist outlines the steps to follow ifyou decide to implement this technology inyour next building project.

DEFINITIONS

PrefabricationManufacturing of structural componenoff site provides a factory-controlledenvironment. Prefabricated panels arenot exposed to weather conditions

during fabrication, and are delivered tothe job site ready to be assembled.

PSI (pounds per square inch)Poured concrete walls usually have adesign strength of 3,500 psi, whereasprecast concrete foundation panels cahave a design strength of 5,000 psi.


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The Partnership for Advancing Technologyin Housing (PATH) is dedicated toaccelerating the development and use oftechnologies that radically improve thequality, durability, energy efficiency, andaffordability of America's housing.Managed by HUD, the PATH partnershipincludes the homebuilding, manufacturing,insurance and financial industries, andFederal agencies concerned with housing.

PATH addresses barriers to innovation,provides information on advanced buildingtechnologies, and advances housingtechnology research; making affordable,quality American homes a reality.

For more information on the PATHprogram, visit www.pathnet.org.

Tech Specs are Prepared for PATH by theNAHB Research Center.

RESOURCESToolBase ServicesInformation on this building technology

and many others brought to you by PATHand the building scientists at the NAHBResearch Center.www.toolbase.org

American Concrete InstituteInternational (ACI)P.O. Box 909438800 Country Club DriveFarmington Hills, MI 48333248.848.3700www.aci-int.org

Canadian Precast PrestressedConcrete Institute100-196 Bronson AvenueOttawa, Ontario, Canada K1R 6H4877.937.2724www.cpci.ca

Fintech Precast16761 Clear Creek Rd.Redding, CA 96001888.837.6522www.fintechprecast.com

Kistner Concrete Products, Inc.8713 Read RoadEast Pembroke, NY 14056

716.762.8216www.kistner.com

National Precast Concrete Associatio10333 N. Meridian Street, Suite 272

Indianapolis, IN 46290800.366.7731www.precast.org

Old Castle Precast2820 A Street SEP.O. Box 608Auburn, WA 98071-0608253.833.2777www.oldcastleprecast.com/Oldcastle_Prast/index.asp

Portland Cement Association5420 Old Orchard Rd.Skokie, IL 60077847.966.6200www.cement.org/homes/ch_bs_panelsyems.asp

Precast/Prestressed Concrete Institut209 W. Jackson Blvd.Chicago, IL 60606-6938312.786.0300www.pci.org

Superior Walls of America, Ltd.937 East Earl Rd.New Holland, PA 17557800.452.WALL (9255)

www.superiorwalls.com

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