Wall Panel Design Manual- Inside Pages 11.23.10

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COLORADO

GEORGIA

OREGON

UTAH

WASHINGTON

Providing Engineered Concrete Solutions

Wall Panel Design Manual

Copyright © 2010 By EnCon Design, LLC

WPM001 11.23.2010 Rev 3

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Introduction

Precast concrete wall panels are an extremely versatile

product. They have the capability to be an integral

component of a traditional building system as well as part

of an entire precast concrete building system. This Wall

Panel Systems Design Manual provides information about

the various types of precast wall panels and building

systems that are available from EnCon Companies, and

the ways each system is best used. Owners, contractors,

architects, and engineers will discover that wall panels can

function in a wide variety of settings and offer a myriad of

benefits. A few of the countless benefits include the

economical, environmentally friendly, and timely

construction compared to traditional building methods.

Every segment of the construction industry can benefit

from the high performance of precast concrete wall

panels. They are an energy‐saving, resilient, and easy‐to‐

maintain building envelope that require minimal upkeep.

In addition, they provide a finished interior hard wall and

eliminate the need for exterior columns for support.

Precast wall panels can be rapidly constructed, are fire

resistant, mold and mildew resistant, and decrease sound

transmission. They also meet unique building needs and

challenges, and offer unrivaled design flexibility in every

area including shape, style, finish, color, texture, and

decorative ornamentation. Thus, when low building costs,

reduced energy expenditure, minimal maitenence, long‐

term durability, and minimal fire insurance rates are

important, a precast wall panel system is the ideal building

arrangement for any structure, whether it be a low‐, mid‐,

or high‐rise edifice. Regardless of the type of design,

EnCon’s precast concrete wall panels and wall panel

building systems provide owners, designers, and

contractors with benefits that are unsurpassed.

The following information includes sections that address

frequently asked questions and technical data, as well as

product cross section details and connection concepts.

Also enclosed are sample specifications and a set of

typical general notes. For further information, or to

discuss a project, please see the contact list on the back

cover of this manual.

Sand Creek High School

Colorado Springs Airport

The Shops at Walnut Creek

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Table of Contents Introduction ................................................................................................................................................................................................ 1 Table of Contents ........................................................................................................................................................................................ 3 Benefits over other Construction Materials ............................................................................................................................................... 5 Product System Use .................................................................................................................................................................................... 5

Residential: Single Family, Multi‐Family, Multiple Unit ......................................................................................................................... 5 Retail ...................................................................................................................................................................................................... 5 Education ............................................................................................................................................................................................... 6 Commercial/Warehouse/Manufacturing ............................................................................................................................................... 6 Office ...................................................................................................................................................................................................... 6 Religious ................................................................................................................................................................................................. 7 Secure Environments: Food Industry, Medical/Laboratory Facilities ..................................................................................................... 7 Judicial and Military ............................................................................................................................................................................... 7

Product Variations ...................................................................................................................................................................................... 8 Manufacturing Tolerances ..................................................................................................................................................................... 8 Color ....................................................................................................................................................................................................... 8 Finish ...................................................................................................................................................................................................... 8 Thermal Efficiency .................................................................................................................................................................................. 8 Loadbearing vs. Non‐Loadbearing (Gravity) ........................................................................................................................................... 9 Typical Combinations ............................................................................................................................................................................. 9 Industrial Grade Wall ........................................................................................................................................................................ 9 Structural Plus ................................................................................................................................................................................... 9 High End Architectural ...................................................................................................................................................................... 9

Product Types ........................................................................................................................................................................................... 10 Shear Walls .......................................................................................................................................................................................... 10 Column Cover ....................................................................................................................................................................................... 10 Spandrels ............................................................................................................................................................................................. 10 Mullions ............................................................................................................................................................................................... 10 Truss Wall ............................................................................................................................................................................................. 10 Truss Wall Advantages .................................................................................................................................................................... 10 CarbonCast® ......................................................................................................................................................................................... 11 CarbonCast® Advantages ................................................................................................................................................................ 11

Building System Variations ....................................................................................................................................................................... 11 Envelope Systems ................................................................................................................................................................................ 11 Loadbearing Systems ........................................................................................................................................................................... 11 Lateral Force Resisting Systems, either Loadbearing or Non‐Loadbearing .......................................................................................... 12 Architectural Enhancement Panels ...................................................................................................................................................... 12

Product System Benefits ........................................................................................................................................................................... 12 Advantages of an EnCon Precast Wall Panel System ........................................................................................................................... 12

Precast vs. EIFS ......................................................................................................................................................................................... 15 Typical Design and Delivery Process ......................................................................................................................................................... 16 Embedded Brick ........................................................................................................................................................................................ 17

Advantages of Embedded Brick over Traditional Masonry .................................................................................................................. 17 Other Benefits Include ......................................................................................................................................................................... 17 Brick Patterns ....................................................................................................................................................................................... 18 Brick Sizes ............................................................................................................................................................................................. 18 Requirements of Embedded Brick Units .............................................................................................................................................. 19 Considerations when Choosing Embedded Brick Wall Panels ............................................................................................................. 19

Frequently Asked Questions ..................................................................................................................................................................... 20 What is a Sandwich Panel? .................................................................................................................................................................. 20 What is a Wythe? ................................................................................................................................................................................. 20 What is a Wythe Tie? ........................................................................................................................................................................... 20 What are R‐values? .............................................................................................................................................................................. 20 What is a Thermal Bridge? ................................................................................................................................................................... 21 What is the Difference between a Composite and Non‐Composite? .................................................................................................. 22 What kind of Insulation is used in Insulated Wall Panels? ................................................................................................................... 22 Why are Wythe Ties and Solid Zones so Important? ........................................................................................................................... 22 How thick is the amount of Insulation in the Panels? .......................................................................................................................... 23

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What size Panels are Available? .......................................................................................................................................................... 23 How are Wall Panels Produced? .......................................................................................................................................................... 23 How is a Wall Panel System Installed? ................................................................................................................................................ 23 Are Precast Wall Panels Resistant to Air Born Debris? ........................................................................................................................ 24 What are the Finish Options? .............................................................................................................................................................. 24 How does Building with Precast Concrete Contribute to LEED® Certification? ................................................................................... 25 What is the PCI Plant Certification Program? ...................................................................................................................................... 27

Common Details ....................................................................................................................................................................................... 28 Wall to Foundation .............................................................................................................................................................................. 29 Wall to Slab on Grade at Dock Door .................................................................................................................................................... 29 Architectural Details ............................................................................................................................................................................ 30 Insulation and Brick Details ................................................................................................................................................................. 31 Wall Panel to Wall Panel Alignment .................................................................................................................................................... 33 Spandrel to Wall Gravity ...................................................................................................................................................................... 33 Wall Panel to Wall Panel Corner .......................................................................................................................................................... 34 Steel Beam Embed Support ................................................................................................................................................................. 34 Steel Joist Bearing ................................................................................................................................................................................ 35 Steel Joist Bearing (Alternative View) .................................................................................................................................................. 35 Steel Deck Support .............................................................................................................................................................................. 36 Steel Beam Bearing Pocket .................................................................................................................................................................. 36 Double Tee Bearing Pocket.................................................................................................................................................................. 37 Double Tee Bearing without Pocket .................................................................................................................................................... 37

Sample set of Project Specifications ........................................................................................................................................................ 38 Sample set of General Notes .................................................................................................................................................................... 40

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Benefits over other Construction Materials There are a variety of wall panel building systems on the market but none compare to or contain the benefits of precast/prestressed concrete.

Product System Use

Residential: Single Family, Multi‐Family, Multiple Unit Precast wall structures are the ideal building system. In

addition to their many benefits, they offer an average

reduction in heating and cooling costs of 50%. The

panels eliminate heat transfer, keeping warm air in and

cold air out in the winter, and the opposite during the

summer months. The safety, security, and high fire

resistance panels keep insurance rates low. Wall panels,

especially insulated panels, minimize noise between

units and help dampen noise outside of the structure.

Precast concrete also helps minimize mold, mildew, and other water related damage by providing superior moisture

control and protection.

Retail Durable and easy to care for, wall panels are perfect for public spaces. A large

variety of surface options make

precast wall panel systems especially well‐suited to retail centers

that desire a particular aesthetic appearance. The rapid

construction time of a wall panel system minimizes initial costs and

enables prompt occupancy and revenue returns.

EnCon PrecastWall Systems

Tilt‐Up Metal Panel Masonry

Design Flexibility X X

Durability X X X

Low Life Cycle Costs X

Low Maintenance X X

Moisture Resistance X X

Plant‐Production for Quality Assurance X X

Thermal Efficiency X X

Year Round Rapid Construction X

Security and Safety X X

Produced Under a Plant Certification Program X

Pikes Peak Harley‐Davidson & Buell

Single Family Residence

The Shops at Walnut Creek

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Education The finished and resilient interior and exterior surfaces of a precast wall system retains its excellent condition and

attractive appearance throughout the life of the structure. Energy efficient insulated panels eliminate the need for

additional insulation, air gaps, and thicker wall sections. Due to its high level of fire‐resistance, precast wall panels

provide advanced safety for students and staff members of educational buildings.

Commercial/Warehouse/Manufacturing Precast wall panel systems offer high value and long life while meeting demanding

requirements. It provides a smooth, hard interior surface that resists abrasive damage

caused by heavy equipment. Also, precast allows for great expanses under the roof

without perimeter support

columns, as well as openings

wider than conventional ones.

This makes it particularly

convenient for loading and

unloading materials and

supplies. Floors can be poured

after the walls are erected and

the roof is in place. This

protects the floor from

construction damage and avoids schedule delays due to inclement weather.

Office Corporate owners and managers profit from the

accelerated occupancy, insurance and tax benefits,

and reduced construction financing that a precast wall

panel system offers. The panels are an excellent

option for an office park environment as exteriors can

be matched to those of other buildings to help new

construction blend with existing structures. This

system also accommodates the moving of walls for

the possibility of future building expansions.

Fox Meadow Middle School

GCC Office, Shop & Warehouse

The Aerospace Corporation

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Religious With a precast wall system, a multitude of aesthetic choices, such as customized designs and finishes, are available to

create nearly any motif. Also, insulated panels provide excellent sound reduction, events held in one space do not

disturb concurrent activities in adjacent spaces. In addition, precast wall panels offer long‐term energy and cost‐saving

benefits with a nearly maintenance‐free façade.

Secure Environments: Food Industry, Medical/Laboratory Facilities Precast wall systems offer clean, germ‐free environments for facilities, such as food‐processing plants and medical

offices, where this is of utmost importance. This is an economical and effective way to meet government standards.

Interior panel surfaces can be given a smooth finish that is easy to clean, free of air voids, and resists soiling. In addition,

the concrete can be microbiotically treated to provide enhanced mildew resistance. Also, ledges that might collect dirt

can be eliminated, and durable interior walls are able to endure the continued application of harsh chemicals.

Judicial and Military Precast wall panels are strong and hard‐wearing for an increased level of safety and security. They resist rust, dents, and

punctures as well as forces of nature that can damage or destroy other buildings. Panels can be produced to exact

specifications in a wide variety of dimensional choices to meet building requirements. Precast insulated panels have

been tested and shown to exhibit exceptional blast resistance, a typical requirement for these facilities.

Eastern Hills Community Church

Fort Carson Division Headquarters

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Product Variations Wall panels are versatile pieces that can be used as architectural, structural, or combination elements. Insulated wall panels can be designed as composite or non‐composite, and loadbearing or non‐loadbearing. In addition, panels can be cast with blockouts for electrical conduit, HVAC ductwork, windows, and entrance and egress openings. Because of the substantial number of variations and combinations of panel configurations and manufacturing tolerances, this manual has provided you with the following list of features that can help with product selection and specification.

Manufacturing Tolerances There are two distinct sets of tolerances in the manufacturing of precast/prestressed concrete. These can include dimensional, surface finish, and color variation. Typical structural grade product is produced under PCI MNL 116 while architectural product is produced under PCI MNL 117. This however should not imply that all product made to PCI MNL 116 is gray and has large variations in dimensions or all exterior façades of structures are produced to the more stringent architectural requirements of PCI MNL 117. Any combination of the quality guidelines can be put together to facilitate the most economical wall panel system while ensuring the aesthetic and architectural intent. As opposed to a painted precast panel, a brick panel would require significantly tighter tolerances. Our Structural Plus panels are manufactured to PCI MNL 116 for dimensional tolerances and PCI MNL 116 for color and surface finish variation.

Color Panel color is developed through a variety of techniques:

Colored Pigment

Colored Aggregate

Surface Finish Variation

Supplemental Material – Paint and Stain Structural Plus panels come in colors based on local aggregates, gray cement, and pigment. Currently, these colors are Gray, Cinnamon Toast, and Cream.

Finish Panel finishes can vary from a form finish, to a very smooth finish, to a heavy exposed aggregate finish. The installation of the finish is a cement or matrix removal process. The material removal can be accomplished with a high pressure sand, or acid and high pressure wash.

Thermal Efficiency These panels can be insulated with limited solid zones to 100 percent thermal efficient. Typical steady state thermal R‐values are on the order of 8 to 15. If thermal mass is accounted for, and the interior surface is the concrete panel or contains a single layer of gypsum, effective R‐values can be on the order of 12 to 22. In addition to R‐values, precast concrete provides the advantage of thermal mass. This benefit enables the storage of heat which is released over time,

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leveling the peak fluctuations in mechanical HVAC equipment demand.

Loadbearing vs. Non‐Loadbearing (Gravity) For the most efficient structural system, the exterior wall panels should be loadbearing. This solution prevents interior columns adjacent to the panels, and eliminates the roof or floor perimeter spandrel beams. Non‐loadbearing panels can be referred to as cladding, or curtain wall systems, and are common building envelopes. They can be connected to any type of structural frame, including precast concrete, cast‐in‐place concrete, or steel. When designated as non‐loadbearing, they are typically designed to resist wind and seismic forces generated by their own weight. Either of these bearing systems can include wall panels with or without windows, spandrels, mullions, or column covers.

Typical Combinations

Industrial Grade Wall

Concrete Color Gray

Surface Finish Paint Ready

Insulation Insulated or non‐insulated

Loadbearing Loadbearing or non‐loadbearing

Inlay Material None

Liner None

Dimensional Tolerance PCI MNL 116

Color and Surface Finish Tolerance PCI MNL 116

Structural Plus

Concrete Color Gray, Cream, Cinnamon

Surface Finish Light to medium sandblast finish Insulation Insulated or non‐insulated


Inlay Material Thin brick, block

Liner Thin plastic liner



High End Architectural

Concrete Color Any variety based on aggregate and pigment

Surface Finish Exposed Aggregate, sandblast, or acid‐etch Insulation Insulated or non‐insulated

Inlay Material Stone, brick, etc.

Liner Stone, brick, etc.




Fox Middle School

Falcon High School

Sand Creek High School

Centralia High School

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Product Types

Shear Walls Shear walls are also structural components and function as part of the lateral resistance system of a building, withstanding forces from wind, blast, or earthquake. They can be load bearing or non‐load bearing and include both solid and window panels. Structural panels can be loadbearing or non‐loadbearing, but are manufactured to PCI MNL 116 tolerances. Loadbearing panels are structural components that transfer gravitational or vertical loads from other elements, and contribute to the strength and stability of a structure. Loadbearing elements include solid wall panels and composite and non‐composite insulated panels, both of which can contain blockouts.

Column Cover A column cover is a precast panel that covers one or more sides of a column.

Spandrels Spandrels are used to fill the space between the top of a window or door in one story, and the sill of the window in the story above, or a parapet. As part of the exterior of a building, spandrel panels span the distance between wall panels that act as columns. These panels can be loadbearing or non‐loadbearing.

Mullions Mullions are structural components that vertically divide adjacent windows and/or doors. They are non‐structural members and do not typically carry any dead load. They will generally only support wind load from the window/door unit, carrying it back to the building structure.

Truss Wall EnCon also provides a metal truss wall. This is a medium performance product that can have an enhanced thermal efficiency over solid panel and panels with solid zones in through the insulation. Prestress steel serves as primary out‐of‐plane flexural reinforcing. A metal truss is used for reinforcing to produce composite shear transfer. The panels are designed as nearly 100% composite and thus require less concrete than a non‐composite panel.

Truss Wall Advantages Composite action between wythes

Lighter panel

Edge to edge Insulation

Minimal thermal bridging

Minimal condensation regions

Increased useable floor area

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CarbonCast® EnCon also provides CarbonCast®. This is a high performance product that can be thermally efficient with carbon fiber reinforcement. Prestress steel serves as primary out‐of‐plane flexural reinforcing. A resin‐bonded, carbon‐fiber grid is used for reinforcing to produce composite shear transfer. Since carbon is non‐corrosive and non‐thermally conductive, it eliminates the risk of internal deterioration and thermal loss. Since the panels are designed as 100% Composite, the panel requires less concrete, allowing the panels to be thinner and lighter weight. In addition, carbon can be used in the panel as transverse reinforcement, limiting the exposure and risk of corrosion.

CarbonCast® Advantages Composite action between wythes

Thinner panel

Lighter panel

Edge to edge Insulation

Minimal to no thermal bridging

Minimal to no Condensation regions

Thermally non‐conductive wythe connections

Increased useable floor area

Building System Variations

Envelope Systems Architectural or non‐loadbearing panels, often referred to as cladding or curtain walls, are the most common use of precast for building envelopes. They can be connected to any type of structural frame, including precast concrete, cast‐in‐place concrete, or steel. Architectural wall panels enclose a space and do not transfer vertical loads. They are typically designed to resist wind and seismic forces generated by their own weight. These precast pieces can include wall panels with or without windows, spandrels, mullions, and column covers.

Loadbearing Systems Loadbearing panels are structural components that transfer gravitational or vertical loads from other elements and contribute to the strength and stability of a structure. Loadbearing elements include solid wall panels and composite and non‐composite insulated panels, both of which can contain blockouts.

CEC Project

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Lateral Force Resisting Systems, either Loadbearing or Non‐Loadbearing Shear walls are also structural components and function as part of the lateral resistance system of a building, withstanding forces from wind, blast, or earthquake. They can be loadbearing or non‐loadbearing and include both solid and window panels.

Architectural Enhancement Panels

Architectural wall panels can be used to enhance the appearance of multiple construction applications. Integrated with steel, stone, masonry, or even cast‐in‐place concrete, highly detailed and ornate panels can dramatically improve the exterior of a structure. Personalized emblems, symbols, or logos add additional visual interest.

Product System Benefits Precast concrete wall panel systems have demonstrated high value and versatility in every market. No other material or system combines as many benefits as a precast wall system.

Advantages of an EnCon Precast Wall Panel System The EnCon Companies have delivered high quality precast concrete structures throughout the United States, and hold a strong commitment to partnership, customer care, and product excellence. From design support to product installation, they maintain a full service, integrated approach to delivery. As a result, clients receive the benefits and convenience of a single source supplier. This helps limit the project risk, as well as the number of subcontracts needed.

Design Flexibility Precast wall panels can be produced in different sizes and depths, offering more design flexibility than other building systems where components may be limited to standard sizes and dimensions. Wall systems can accommodate nearly any design requirement, unusual lengths and widths, wide openings, and varying wall thicknesses. Specially constructed forms allow for the casting of curved or radiused panels to create uniquely shaped buildings. Panels can be cast with blockouts for windows, ductwork, and electrical, as well as entrance and egress openings. Panels can also be fabricated with pre‐installed windows and stud nailers applied at the plant. The entire panel can then be lifted into place with minimum preparation.

Aesthetically Versatile Exteriors Precast is an extremely adaptable material and offers unlimited aesthetic options. Exterior surfaces can be finished to complement the surrounding landscape as well as match the design of an existing structure. Precast easily accommodates the use of other building materials to create a cohesive appearance. Unique and intricate personalized designs can be cast into the panels using form liners. This makes it easy to add details such as

Folsom Field Addition

University of Colorado at Colorado Springs Dorms

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reveal patterns, names, emblems, and symbols. Multi‐color paint treatments can further highlight architectural features. Panels can be produced in one or multiple colors, and also in a variety of textures and aggregates. A variety of surfacing techniques may also be applied to the panels. These include sandblast, acid‐etch, trowel, polishing, stain, and paint. The results can include a smooth, ribbed, or exposed aggregate finish. They can also replicate the appearance of wooden boards. Furthermore, panels can also be clad in brick, tile, terra cotta, limestone, sandstone, granite, marble, or stone.

Interior Surfaces Panels create a double‐wall system where the interior walls are essentially prefinished, eliminating the need for and expense of additional surface treatments, including drywall. A wide variety of finishes, including paint, can be applied to the panels if desired. Intermediate bracing is not needed, as panels typically offer clear heights of 30 ft creating unobstructed use of the full interior height of the building.

Economical EnCon’s precast wall panels are an excellent budget‐conscious choice that does not sacrifice high quality. Wall panel systems are cost competitive with other systems that do not offer the benefits of precast. Fabrication on a permanent long line facility allows for more panels to be cast simultaneously, resulting in decreased labor costs and an accelerated project schedule. Precast wall systems facilitate building expansions, which help keep future construction costs to a minimum.

Expedited Construction Schedule Wall panel systems can be cast at the manufacturing facility simultaneously with job‐site preparation and there is no need to cast the interior slab before panel erection. Thus, installation can begin immediately following delivery. In addition, the availability of large panel sizes means fewer panels to be cast and erected. EnCon’s wall panels and systems can be fabricated and erected in inclement weather conditions and in environments that would otherwise interfere with building construction. Finished interior walls also eliminate the time and expense of furring strips and drywall.

Green Construction Sustainable, thermally efficient, and having low life cycle costs, a precast wall system is an excellent building solution in today’s environmentally‐conscious climate. Plant fabrication results in reduced construction time and less job‐site waste and congestion, all of which have less of an impact on the landscape. Unlike other building and framing materials, precast concrete does not release toxins when burned. Concrete provides thermal mass, which delays heat transfer through building walls and moderates indoor temperature fluctuations as outdoor temperature varies. Along with lowering heating and cooling costs, this helps to meet stricter energy requirements. With integral insulation, high‐performance sandwich panels further reduce energy consumption, forgoing the need for extra insulation. Typical R‐values can range from 8 to more than 18.

High Quality Plant casting yields a more predictable product with greater quality control, consistency, and finish. With focus placed on ultimate strength rather than cure time and temperature, precast wall panels are stronger than concrete blocks or walls that are cast on‐site and tilted into place. Prestressing reinforcement yields inherent structural and serviceability advantages, such as increased strength, ductility, crack control, and panel flatness.

Safety and Security Precast concrete is naturally fire resistant while wall panel systems inhibit fire spread. This helps to ensure a blaze remains contained. Consequently, more time is provided for fire detection, evacuation, and suppression. Wall panels protect a building from the spread of adjacent fires and aid in compliance with special building code requirements. Foam blockouts are used to accommodate plumbing, mechanical, and electrical penetrations. This minimizes the amount of on‐site core drilling and decreases job‐site risk. Precast concrete’s structural stability provides resistance to damage caused by forces of nature that including seismic events. Wall panels can be treated and finished to create a room free of dust, particles, and other contaminants. These characteristics are of particular importance to healthcare and research facilities.

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Moisture Resistance and Acoustical Control Fabricated with a low water‐to‐cement ratio, highly dense precast concrete inhibits water penetration. Precast wall panels eliminate the need for drywall, supplying an added measure of protection against mold and mildew growth. Panels, especially insulated panels, diminish noise transmission for greater privacy and reduce sound transmission from outside a building to the inside.

Loadbearing vs Non‐Loadbearing The wall panel system can function as a structural loadbearing element as well as an architectural skin. This eliminates the need for floor and roof support framing. In many cases, spread footings are not necessary as a special built‐in beam feature at the base of a panel enables it to span from caisson to caisson.

Fire Resistance Fire ratings are based on a Rational Fire Design calculation method or an IBC Prescriptive Fire Rating method. A fire rating is dependent upon equivalent thickness, heat transmission thickness, cover on the prestressing strand, and end restraint. A standard 8 in.‐thick Hollow Core system has a two hour fire rating. However, higher ratings (three or four hour) may be achieved with topping and gypsum board, or the application or a spray‐on, fire‐resistant material to the underside of the slab.

Blast Resistance Insulated wall panels have been shown to hold superior strengths and energy absorption characteristics. This has been revealed through recent, full scale testing and blast simulations with end results that place precast wall systems high above traditional building methods.

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Precast vs. EIFS EnCon’s precast products stand up to other options within the industry as the premier building system. The quality of EnCon’s Insulated Precast Concrete Products is unsurpassed as each piece is engineered against cracking under all service conditions. Their products are predominantly used for the exterior building envelope and are designed

to prevent moisture infiltration into the structure, for the life of the structure. In addition, many of the products are prestressed, a reinforcing technique developed to increase span, capacity, and decrease the propensity for cracking. Because of the high standards placed on the precast design and manufacturing process, it is a more durable and efficient choice than its counterparts within the industry.

EIFS, an alternative to precast, is a finishing technique in which crementitious top and base coats are applied to Expanded Polystyrene Insulation. The insulation is then applied directly to the structured sheeting either through glue or mechanical fasteners. Due to this method of construction, the finished exterior can be somewhat soft and susceptible to cracking, indentations, and penetrations, damaging the finished surface. In turn, water infiltration and mold become common problems. Another form of EIFS consists of a pre‐manufactured panel of insulation with a structural metal frame coated in a thin base and finish coat. Although this is a similar concept to that of a precast panel, the EIFS Panel system is typically not engineered for rigidity or to prevent surface cracks. The latest EIFS system designs have included a vapor barrier between the insulation and sheathing. Although this provides better moisture control in the field, portions of the insulation and mechanical fasteners still penetrate this membrane and create a potential source of moisture intrusion.

Insulated Concrete Wall Panel

Typical EIFS Cross Section

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Typical Design and Delivery Process The flow chart below highlights the general process from project initiation to completion. The tables contain representative project schedules and demonstrate the primary scheduling benefit of precast concrete construction. There are a number of interrelated yet overlapping activities that allow faster turnaround and quicker job completion.

Preliminary

Design Assistance

Project Identification

Estimate and Award Project

Final Design Calculations,

Erection Drawings, and Details

Manufacture, Store, and Transport

Final Erection and Production

Drawings

Erection and Field Finish

Project Completion

Submittal and Approval

Process

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Embedded Brick When thin brick is cast into concrete wall panels, this produces embedded brick; a material that can be implemented to create an entire structure as well as decorative elements on a building façade.

Advantages of Embedded Brick over Traditional Masonry Along with aesthetic appeal and low cost, there are numerous benefits surrounding brick‐embedded concrete over conventional masonry. These include no lintels, flashing, weep cavities, air space, waterproofing, or efflorescence. In addition, there is no time‐consuming, on‐site construction of masonry products.

Other Benefits Include: Pleasing traditional appearance of brick, while leveraging

the strength, speed, and economy of precast concrete

Due to low absorption rates, thin brick is rated not to

effloresce

Inlaid thin brick walls required no periodic sealing or tuck‐

pointing repair

Thin brick precast conforms to PCI standards for brick

embedded in precast

Rose Medical Center

Split‐face Inlay

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For those seeking a brick finish that is both visually appealing and economical, EnCon offers thin brick wall panels that come with various options including a range of finishes, sizes, and shapes of brick. There are also pieces that are used to create architectural corners, arches, soldier courses, and other traditional brick patterns.

Brick Patterns Brick Sizes

Running Bond Flemish Bond Stack Bond English Bond

Arches Numerous Bonding Patterns Ornate Corbels

Soldier Course

Norman Brick

Modular Brick

Utility Brick

Brick Corner

Edge Cap

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Requirements of Embedded Brick Units

Have dimensional tolerances +0 in. ‐1/16 in. on all units 8 in. or under; +0 in. ‐3/32 in. on all units larger than 8 in.

Have a 24‐hour cold water absorption rate nor more than 6% when tested per ASTM C67

Maintain a consistent plane of +0 in. ‐1/16 in. (+0 ‐1.6 mm)

– All Shapes shall confirm to the architect’s specified angle with a tolerance of ±1˚ (Measured per ASTM

C67)

Maintain an out‐of‐square dimension ±1/16 in. (±1.6 mm). Measure per ASTM C67

Rate “not effloresced” per ASTM C67

Exhibit minimum tensile bond strength or 150 psi (1.0MPA) when tested per ASTM C482

Exhibit no detectable deterioration (spalling, cracking, chafing, etc.) when tested in accordance with ASTM

C666 Method B, modified to withstand 300 cycles

Be shown to demonstrate minimum of modules of rupture or 250 psi per (1.7MPA) when tested in accordance

to ASTM C67

Rate “not affected” by chemical attack when tested per ASTM C650

Considerations when Choosing Embedded Brick Wall Panels A number of things should be considered during the design and detailing of each specific project. These include brick and panel sizes and shapes, loadbearing conditions, panel openings, and brick panel tolerances.

Modular brick sizes should be used when determining panel widths, heights, and openings.

The use of concrete banding at the edges of precast panels and openings should be considered. Banding can minimize the cost of having to cut brick to odd sizes, or the need to build panels to sizes that only fit the module of the brick. Banding helps with this by creating a solid concrete face along a panel edge to which the brick is set against. It can also be used to differentiate floor locations, panel joints, and other architectural effects. Banding also permits panel heights, widths, and opening sizes to be nearly any dimension, independent of brick coursing.

It is vital that masonry coursing be continuous from panel to panel, both vertically and horizontally. This is important when concrete banding is not used at the edge of panels.

When a formliner pattern that is rectilinear or modular is used, aligning the brick pattern with the concrete pattern should be considered. This will help to align openings in the different patterns, as well as create a well‐ordered, visually pleasing façade.

When using concrete banding at jambs of window or door openings, ¾ in. is the minimum recommended concrete jamb band width.

Precast header and sill heights and lengths should be placed symmetrically within the brick modular pattern.

Corner brick can be used for both panel ends and brick returns at window and door heads and jambs. Opening sizes should fit symmetrically within the brick module. Please note that creating opening sizes to fit the brick module may require ordering custom size windows.

Although it is more costly than using standard modular sizes, cutting brick to special sizes at edges of panels and panel openings can be achieved if necessary. If a special size opening is required, the opening should be located so that the brick is cut equally on either side of the opening.

Industry standard manufacturing tolerances of both precast panels should be considered during the design of each project.

Tolerances that should be taken into consideration include floor‐to‐floor heights, panel heights, brick coursing, joint sizes, loadbearing conditions, and joint details.

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Steady State R‐Value

Air Infiltration

Thermal Mass

Foundation Conectivity

Floor System

Geographic Position

Humidity

Thermal Shorts

Daily Temperature

Range

Effects of Analysis Duration

Frequently Asked Questions The following section relates to typical questions regarding wall panels, specific terms and properties, and the manufacturing and erection process.

What is a Sandwich Panel? Insulated wall panels are also referred to as sandwich panels. An inner core of insulation is surrounded or sandwiched between two precast concrete layers or wythes.

What is a Wythe? A wythe is a layer within, or on the surface of a sandwich panel or insulated wall Panel.

What is a Wythe Tie? A Wythe Tie is the name of the material that connects two or more layers of concrete (wythes) together in an insulated wall panel.

What are R‐values? R‐value, or Thermal Resistance, is one measurement of the thermal performance of a system. There are two types of R‐values discussed in the construction industry. These are Steady State R‐values and Effective R‐values. The Steady State R‐value is traditionally based on the measured, one dimensional resistances of the construction materials that comprise the system for a given assembly of materials. Although there are a number of factors that influence R‐values, the Effective R‐value is primarily a combination of Steady State R‐value and Thermal Mass. There are no standard methods of calculating Effective R‐values. One method, however, is the development of a multiplier for mass wall systems or the Dynamic Benefit for Massive Systems (DBMS). This multiplier relates the Steady State R‐values to Effective R‐values using a standardized lightweight wood frame structure as a base line. The standardized home is modeled with each wall system in order to determine the total building energy load for a given duration and climate. The Steady State R‐value of the exterior wall system for the standardized lightweight wood framed home is then manipulated until the energy loads are the same as the mass wall system in question. The ratio of the Steady State R‐value of the modified wood structure to the Steady State R‐value of the mass wall system is equal to the DBMS. One benefit of this approach is that it allows for the evaluation of similar mass wall construction techniques, wall assemblies of sandwiched insulation, and wall assemblies of sandwiched concrete. The industry standard for thermal performance comparison should be a comparison of Steady State R‐values. This method is an excellent predictor of R‐values with variations in material thickness, solid zones, or thermal shorts. It has been adopted by the Precast and Prestressed Concrete Institute Design Handbook as the preferred method of calculating R‐values for complex assemblies.

Factors that Impact the Thermal Performance of a Structure

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What is a Thermal Bridge? The inner and outer concrete thicknesses of a typical precast insulated wall panel are called wythes, and are connected together with wythe ties. These ties can be made of steel, carbon fiber, or solid zones of concrete. It is the intent of most designers to minimize these ties to prevent thermal shorts or thermal bridging. A thermal bridge is a component, or assembly of components, in a building envelope in which heat is transferred at a substantially higher rate than through the surrounding envelope area. It consists of a thermally conductive material that penetrates or bypasses an insulation system such as a metal fastener or concrete beam. A thermal bridge is created when materials that are poor insulators come in contact, allowing heat to flow through the path that is generated. Because of thermal bridging, insulation around a bridge is of little help in preventing heat loss or gain.

Typical effects of thermal bridges include:

Decreased interior surface temperatures; in the worst cases this can result in condensation problems, particularly at corners

Significantly increased heat losses

Cold areas in buildings.

Surface moisture due to condensation, may occur in such regions as floor to wall connections, window installations, etc., as well as mold growth in humid environments can also be effectively prevented by means of multi‐dimensional evaluation during planning and detail design. Concrete balconies that extend the floor slab through the building envelope are also a common example of thermal bridging.

Brick Tie Image

Temperature Results 12 in. Brick and Block Wall

Temperature Scale

Brick Tie Thermal Image

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What is the Difference between a Composite and Non‐Composite? A panel is classified by the amout of composite action it has, or the amount of interaction between the two layers of concrete it holds. The more composite action a panel has, the more the two layers act together, and the stiffer the panel. The less composite action, the more each layer acts independent, and the less stiff the panel. Composite wall panels are insulated sandwich panels with wythes that act as a single unit under loadbearing and non‐loadbearing conditions. Composite shear connectors, or composite wythe ties, enable the member to act as one single unit with the same structural functionality similar to a solid panel of similar thickness, only with less concrete. Less concrete equates to less weight, making the panel more efficient for the same application as a solid panel. Since the inner concrete wythe is thinner there is more usable interior space. Non‐composite panels contain connectors or wythe ties that allow the concrete layers to act independently. These panels are typically heavier than composite panels and must be thicker to perform the same structural tasks.

What kind of Insulation is used in Insulated Wall Panels? Insulated panels contain two wythes of precast concrete and an interior core of foam insulation. The insulating foam R‐values are two to three times greater than most other insulating materials of the same thickness, such as fiberglass or cellulose. There are two primary types of insulation. These are expanded polystyrene foam and extruded polystyrene foam. Expanded polystyrene foam (EPS), commonly known as “beadboard,” is a closed‐cell foam board containing small beads of polystyrene which are expanded by heat. EPS has a typical density of 1 ½ to 2 pounds and offers long‐term R‐value, strength, stability, and water resistance. Extruded polystyrene foam (XPS), also a closed‐cell material, is comprised of polystyrene that is chemically liquefied and forced through a shaping die.

Why are Wythe Ties and Solid Zones so Important? No matter how much insulation is in a system, certain wythe tie methods, such as metal and solid zones, create thermal bridges that dramatically reduce the insulation’s effectiveness. These “thermal shorts” create cold spots that may produce condensation which could potentially develop into other problems.

1. Value obtained summing R‐values for concrete and insulation layers, no air films included. Source: “Summary of Thermal

Tests of Insulated Concrete Sandwich Walls U.S. Dept. of Energy 1998‐1999.

Nearly all brick and block systems contain metal tiles to laterally support the exterior brick face. The cold spots, produced by these thermal shorts, increase the passage of the exterior environment to the interior environment creating an increase in the interiors heating and cooling demand.

Panel Description 3‐2‐3 panels made with extruded polystyrene

Material R‐value1 Test R‐value1

Percent Loss

Panel with steel wythe ties 10.48 7.55 27.96%

Panel with solid zones 10.48 5.77 44.94%

Panel with solid zones and steel wythe ties 10.48 4.56 56.58%

Panel with low thermal conductivity FRP connections 10.48 10.57 ‐0.86%

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How thick is the amount of Insulation in the Panels? The typical thickness is 2 in. However, this is normally a minimum. Depending upon the required R‐value, insulation thickness can reach up to 6 in.

* R-value does not account for combined materials. This is the R-value for insulation only.

What Size Panels are Available? 10 ft 0 in. to 12 ft 0 in. widths are standard. However, widths of up to 13 ft 4 in. can be manufactured. Panels can extend over several floors in height with a preferred maximum height of 50 ft 0 in.

How are Wall Panels Produced? Precast panels are formed by placing concrete into a series of molds or forms.

How is a Wall Panel System Installed? Wall panels should be installed by skilled technicians with experience in erecting precast concrete. The panels are to be positioned and connected to the structure in accordance with engineering calculations, drawings, and details. Other factors that should be considered in the erection of a wall panel system are site access, crane access, sequence and starting position, as well as the results of a site survey to ensure proper elevations and building geometry before the start of erection.

Insulation Thickness

Expanded Polystyrene

(EPS)

Extruded Polystyrene

(XPS)

R‐value* ∙ ∙

2 inches 8 10

4 inches 16 20

6 inches 24 30

Forming and Setup Concrete Placement Finished Surface Preparation Product Storage

Transporting Tripping Rotating to Vertical

Placement

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Are Precast Panels Resistant to Air Born Debris? The following pictures have been captured from a video courtesy of The Precast Concrete Institute, Portland Cement

Association, and PCA and Dukane Precast Inc. The projectile, a wood 2 x 4, was delivered from a 100 mph air cannon

into a thin brick insulated precast sandwich panel and a traditional steel brick face commercial wall system. There is no

sign of projectile penetration in the precast wall panel, while the traditional commercial system clearly shows signs of

penetration into the space of the interior of the structure.

What are the Finish Options? From a simple paint treatment to a more complex acid‐etch technique, EnCon has a finish to fit every budget. When the concrete is poured into a horizontal bed, the bottom, or form side of the panel, is usually the exterior façade, while the top serves as the interior wall. This creates a double wall system. Interior surfaces can range from a single‐pass Fresno to a multi‐pass trowel. Paint or stain may also be applied to coordinate with any color scheme.

Thin Brick Insulated Precast Sandwich Wall Panel

Traditional Commercial Construction: Brick Veneer with 2 x 6 Steel Stud Framing

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Exterior finishes include paint and stain applications, acid‐etch, exposed aggregate, sandblast, and a countless number of patterns shaped with form liners.

How does Building with Precast Concrete Contribute to LEED® Certification? The Leadership in Energy and Environmental Design (LEED) green building rating system is a national standard for developing energy efficient and sustainable buildings. Applying green building practices can yield both energy and cost savings over the life of the structure, have less negative impact on the surrounding ecology, as well as increase the life of a building. Precast is the most widely used building material and has many attributes that make it more preferable than cast‐in‐place concrete and other traditional building systems. The use of precast is less destructive to the natural environment:

1. Plant casting reduces the resources needed for on‐site formwork and decreases waste generated at the construction site.

2. As precast components are installed more quickly, construction time is faster with less on‐site congestion, noise, and emissions from equipment.

3. Less material is required to achieve loadbearing capacity similar to that of other building systems. Precast concrete conserves both resources and materials:

1. Precast contains recycled materials that would otherwise go to landfills. By‐products of other industries, such as fly ash, slag, and silica fume can be incorporated into concrete. These supplementary materials enhance the performance of precast and also reduce the amount of cement that is used in concrete.

2. Precast pieces can be recycled and may be rearranged or removed to accommodate building additions. They can also be reused in other applications.

3. Concrete itself can be recycled as fill or road base and can be reused to protect shorelines. 4. Most reinforcing bars are manufactured from recycled steel.

Paint treatment applied to Gray Insulated Wall Panels

Acid‐Etch Exposed Aggregate Sandblasted Exposed Aggregate/Acid‐Etch

Brick Reveals Stone Wooden Boards

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5. As precast is usually made from regional elements, the need for extensive transportation of ingredients is eliminated.

Precast concrete’s inherent thermal mass and heat‐storage capacity offer major advantages to maximize energy performance. Insulated wall panels provide even greater thermal efficiency.

Falcon High School Seeking LEED® Certification Silver

Fort Carson Brigade and Battalion Headquarters First LEED® Gold Certified building in the Military

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What is the PCI Plant Certification Program? PCI’s Plant Certification Program ensures that each plant has developed and documented an in‐depth, in‐house quality system based on time‐tested, national industry standards. PCI Certified plants are audited in accordance with standards published in three PCI quality‐control manuals (MNL‐116, MNL‐117, and MNL‐130). Precasting plants can be certified in as many as four product groups:

Group A – Architectural Products

Group B and BA – Bridge Products

Group C and CA – Commercial (Structural) Products

PCI's plant certification program as compared to those offered by the National Precast Concrete Association (NPCA) and the Architectural Precast Association (APA):

Criterion PCI NPCA APA Comment

Structuralproducts (prestressed)—established 5 years or more

X

Established, proven experience demanded by the construction industry. High structural capacity, long‐term durability, and serviceability of both conventionally reinforced and prestressed concrete products, all of which are directly influenced by the manufacturer’s quality and production operations. Prestressing operations are performed by properly trained plant personnel supervised by certified quality‐control personnel.

Precast concrete product (conventional reinforcement)

X X High‐quality manufacturing of conventionally reinforced products, which are often non‐structural and non‐architectural in nature.

Architectural precast concrete X X

More stringent tolerance and appearance requirements for architectural precast concrete products than for conventional or structural precast concrete products. Architectural precast concrete products that not only look good, but are manufactured to maximize long‐term durability and desired function.

P.E. inspection/oversight X X X Verifiable proof, provided by professional engineering registration, of a minimum level of competence, experience, and education.

All inspections unannounced X X A more accurate measure of a plant’s routine compliance with required quality operations and manufacturing practices, leading plants to maintain constant vigilance and a strong focus on quality.

Minimum 2 inspections per year

X X Ongoing compliance with quality and manufacturing requirements. A plant quality system that incorporates the latest techniques and is operating properly on a regular basis.

Approval of plant QC manual X X

Review and approval of a plant’s internal quality manual prior to conducting an audit to verify that a plant has addressed all of the critical factors throughout the quality system. A quality manual that clearly addresses each product group and category that the plant manufactures.

Mandatory for PCI Producer Members

X

Mandatory participation for members, which indicates that an organization truly believes in and supports quality in the industry. All members’ plants are operated with established processes and professionalism because their organization requires certification as a prerequisite for membership.

Personnel certification X

Properly trained plant personnel, who are critical to ensuring production of high‐quality precast concrete products. Verifiable proof of proper personnel training, which creates a positive credential that can be used in job advancement. Expiration dates for personnel training and certification, requiring periodic recertification with verification of qualifications and competence assessments.

Field certification X Extension of the demanding quality standards required with plant certification to the process of erecting the finished precast concrete components at the site. Erection to nationally recognized standards.

Quality‐control (QC) manuals X X X

Exposure to detailed and comprehensive quality‐control manuals that provide the basis for proper personnel training and each plant’s manufacturing and quality operations, with specific information to ensure uniform interpretation of both requirements and supplemental commentary.

© 2008 Precast/Prestressed Concrete Institute

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Common Details The details on the following pages are non‐cross section specific and are applicable in standard loadbearing and non‐loadbearing conditions. In addition, they can be used as generic details for insulated panels. Although these are not the only design options available, they are often used as starting points for job‐specific sections and detail requirements. Connection details will vary slightly depending on whether the slab was produced using a dry cast extrusion or a slip form technique. Designers are strongly encouraged to discuss potential details with the fabricator during design development.

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Wall to Foundation

Wall to Slab on Grade at Dock Door

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Architectural Details

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Insulation and Brick Details

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Insulation and Brick Details

33

Wall Panel to Wall Panel Alignment

Spandrel to Wall Gravity

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Wall Panel to Wall Panel Corner

Steel Beam Embed Support

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Steel Joist Bearing

Steel Joist Bearing (Alternative View)

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Steel Deck Support

Steel Beam Bearing Pocket

Note:This detail cannot occur at each end of the same Tee.

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Double Tee Bearing Pocket

Double Tee Bearing without Pocket

Note:This detail cannot occur at each end of the same Tee.

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Sample set of Project Specifications 1.01 SECTION INCLUDES

A. Structural, Architectural and Insulated wall panels, related connection plates, brackets, hangers, and grouting of horizontal joints.

1.02 RELATED SECTION A. Section 03410 – Structural Precast Concrete, Structural Precast Concrete with Commercial Architectural Finish B. Section 03450 – Architectural Precast Concrete 1.03 REFERENCES

A. ACI 301 – Structural Concrete for Buildings. B. ACI 318 – Building Code Requirements for Structural Concrete. C. ASTM A36 – Structural Steel. D. ASTM A153 – Zinc Coating on Iron and Steel Hardware. E. ASTM A416 – Uncoated Seven‐Wire Stress‐Relieved Steel Strand for Prestressed Concrete. F. ASTM A615 – Deformed and Plain Billet‐Steel Bars for Concrete Reinforcement. G. ASTM A666 – Austenitic Stainless Steel, Sheet, Strip, Plate, and Flat Bar for Structural Applications. H. ASTM C150 – Portland cement. I. ASTM C618 ‐‐ Fly Ash. J. ASTM C33 ‐‐ Aggregates. K. ASTM C260 – Air Entrainment Admixtures. L. ASTM C494 – Water Reducing Agents. M. AWS D1.1 – Structural Welding Code. N. AWS D1.4 – Structural Welding Code – Reinforcing Steel. O. PCI Manual For The Design of Hollow Core Slabs. P. PCI MNL‐116 – PCI Structural Quality Control Manual. Q. PCI MNL‐117 – PCI Architectural Quality Control Manual. R. PCI MNL‐120 – PCI Design Handbook. S. PCI MNL‐123 – PCI Connections Manual. T. PCI MNL‐124 – PCI Design for Fire Resistance of Precast Prestressed Concrete. U. PCI MNL‐127 – PCI Erection Tolerances. V. PCI MNL‐135 – Tolerances for Precast and Prestressed Concrete. W. IBC – International Building Code.

1.04 DESIGN REQUIREMENTS A. Size components to withstand design loads. B. Concrete: Minimum compressive strength of 5000 psi at 28 days and 2500 psi at release. C. Design components to accommodate construction tolerances, deflection of other building structural members and clearances of

intended openings. D. Grout and connections at joints to resist lateral and gravity loads or the structure. Calculate structural properties of framing

members in accordance with ACI 318.

1.05 SUBMITTALS A. Shop Drawings: Indicate wall locations, unit identification marks, connection details, edge conditions, bearing requirements,

support conditions, dimensions, openings, openings intended to be field cut, and relationship to adjacent materials. B. Product Data: Indicate standard component configuration and design loads. C. Fabricator’s Installation Instructions: Indicate special procedures and conditions requiring special attention.

1.06 QUALITY ASSURANCE A. Perform work in accordance with the requirements of PCI MNL‐116 or PCI MNL‐117_, PCI MNL‐123, and PCI MNL‐120. B. Maintain plant records and quality control program during production of precast walls. Records available upon request.

1.07 QUALIFICATIONS A. Fabricator: Company specializing in manufacturing the work of this section and PCI certified. B. Erector: Company specializing in erecting the work is recommended. C. Design precast concrete members in accordance with MNL‐120 “PCI Design Handbook – Prestressed and Precast Concrete”, under

direct supervision of a Professional Engineer experienced in design of this work and licensed in the state of the project. D. Welder: Qualified in accordance with AWS D1.1.

1.08 REGULATORY REQUIREMENTS

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A. Conform to ACI 318 code for design load and on‐site construction requirements. B. Conform to PCI MNL‐124, PCI MNL‐116 or 117 for architectural,.

1.09 PRE‐INSTALLATION CONFERENCE

A. Discuss anchor and weld plate locations, sleeve locations, and cautions regarding cutting or core drilling.

1.10 DELIVERY, STORAGE, AND HANDLING A. Lifting or Handling Devices: Capable of supporting member in positions anticipated during manufacture, storage, transportation,

and erection. B. Mark each member with production identification and orientation (if required.)

1.12 COORDINATION A. Coordinate work under provisions of separate section.

2.01 FABRICATORS – PCI Certified Plant 2.02 MATERIALS

A. Materials: To be in conformance with ACI 318. B. Tensioning Steel Tendons: ASTM A416 Grade 270. C. Reinforcing Steel: ASTM A615 or A706, deformed steel bars. D. Sand ‐ Cement Grout: Sufficient for placement and hydration.

2.03 ACCESSORIES A. Connecting and Supporting Devices: Conform to PCI MNL‐120 plates, angles, items cast into concrete, items connected to steel

framing members, and inserts; ASTM A36 carbon steel. B. Steel shims as required by design

2.04 FABRICATION A. Conform to AWS D1.4 and PCI MNL‐116 or 117 for architectural. B. Embed anchors, inserts, plates, angles, and other items at locations indicated. C. Provide openings required by other sections at locations indicated. Greater than 12 inches square or in diameter.

2.05 COMPONENTS A. Nominal Thickness: As required by the project B. Nominal Width: As required by the project

2.06 FINISHES A. Plant Finish: Finish members to PCI MNL‐116 Finish B Grade.

2.07 FABRICATION TOLERANCES A. Conform to PCI MNL‐116 or MNL‐117

2.08 SOURCE QUALITY CONTROL AND TESTS

A. Provide testing and analysis of site‐placed concrete and grout under provisions of Section 01400. B. Maintain shop inspection and testing reports for stressing tendons. C. Test samples in accordance with specified ASTM and ACI standards.

3.0 ERECTION

A. Erect members without damage to structural capacity, shape, or finish. Replace or repair damaged members. B. Align and maintain uniform horizontal and end joints as erection progresses. C. Install bearing material or shims at bearing ends of walls as indicated or necessary. D. Adjust differential elevation between precast members to tolerance before final attachment and grouting. E. Secure units in place. Grout horizontal joints as per shop drawings. F. Perform welding in accordance with AWS D1.1.

3.03 ERECTION TOLERANCES A. Erect members level and plumb within allowable tolerances. B. All work to conform to PCI MNL‐127 and PCI MNL‐135.

3.04 PROTECTION OF FINISHED WORK A. Protection of members from damage from other trades by General Contractor throughout the job.

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Sample Set of General Notes

This section includes generic General Notes that may be found on erection drawings or contract documents. 1. Precast units to be designed, detailed, manufactured, delivered, and installed by EnCon as per contract.

2. General Contractor to provide free and adequate access at job site for delivery, including temporary roadways, crane pad, and

crane path. 3. Wall panels must be lifted with slings or lifting eyes unless noted otherwise. 4. Do not lift, store, or support walls other than as detailed by engineered criteria.

5. Use shims under ends of walls bearing on precast and cast‐in‐place concrete.

6. Plumb and level the wall and grout horizontal joints.

7. Grouting of horizontal wall joints by EnCon as per contract. 8. All openings under contract must be shown on this layout unless noted otherwise.

9. Any drilling or cutting of holes 12 in. or smaller in any direction is by others.

10. No prestressing strand and/or reinforcing shall be cut in field unless approved by EnCon Design.

11. All holes must be approved by EnCon Design in writing prior to drilling or cutting. 12. All trades are to remain out of “control access zone” areas until field crews have completed erecting, leveling, and grouting.

13. Modifications required due to field survey may be the responsibility of the General Contractor.

14. Any and all hardware supplied by EnCon is indicated by a unique and distinct number on the erection drawings. All other

hardware shown is by others even if not explicitly stated. 15. Unless the wall is supported on precast, the General Contractor shall be responsible for providing true and level bearing

surfaces for its support.

16. Joint sealants and caulks are excluded by EnCon and supplied and installed by the General Contractor.

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Contact List:

80 DeHunt Drive Buchanan, GA 30113 770.646.1888

8600 Welby Road PO Box 29039 Denver, CO 80229 303.287.4312

101 South Industrial Loop Road Tooele, UT 84074 435.843.4230

3210 Astrozon Boulevard Colorado Springs, CO 80910 719.390.5041

Stresscon Denver Metro Division 5434 Grand View Boulevard Dacono, CO 80514 303.659.6661

2140 South Ivanhoe, Suite 100 Denver, CO 80222 303.298.1900

5415 189th Street East Puyallup, WA 98375 253.846.2774

1615 SE 6th Avenue Camas, WA 98607 360.834.3459

2140 South Ivanhoe, Suite 100 Denver, CO 80222 303.298.1900

Wall Panel Design Manual- Inside Pages 11.23.10

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