COLORADO

GEORGIA

WallPanelDesignManual
OREGON

UTAH

WASHINGTON

ProvidingEngineeredConcreteSolutions

Copyright 2010
By EnCon Design, LLC
WPM001
11.23.2010 Rev 3

Introduction

Precast concrete wall panels are an extremely versatile

product. They have the capability to be an integral
componentofatraditionalbuildingsystemaswellaspart
of an entire precast concrete building system. This Wall
PanelSystemsDesignManualprovidesinformationabout
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,andengineerswilldiscoverthatwallpanelscan
functioninawidevarietyofsettingsandofferamyriadof
benefits. A few of the countless benefits include the
economical, environmentally friendly, and timely
constructioncomparedtotraditionalbuildingmethods.

Every segment of the construction industry can benefit

from the high performance of precast concrete wall
panels.Theyareanenergysaving,resilient,andeasyto
maintain building envelope that require minimal upkeep.
Inaddition,theyprovideafinishedinteriorhardwalland
eliminate the need for exterior columns for support.
Precast wall panels can be rapidly constructed, are fire
resistant,moldandmildewresistant,anddecreasesound
transmission. They also meet unique building needs and
challenges, and offer unrivaled design flexibility in every
area including shape, style, finish, color, texture, and
decorativeornamentation.Thus,whenlowbuildingcosts,
reduced energy expenditure, minimal maitenence, long
term durability, and minimal fire insurance rates are
important,aprecastwallpanelsystemistheidealbuilding
arrangementforanystructure,whetheritbealow,mid,
or highrise edifice. Regardless of the type of design,
EnCons precast concrete wall panels and wall panel
building systems provide owners, designers, and
contractorswithbenefitsthatareunsurpassed.

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
coverofthismanual.

SandCreekHighSchool

ColoradoSpringsAirport

TheShopsatWalnutCreek

TableofContents
Introduction................................................................................................................................................................................................1
TableofContents........................................................................................................................................................................................3
BenefitsoverotherConstructionMaterials...............................................................................................................................................5
ProductSystemUse....................................................................................................................................................................................5
Residential:SingleFamily,MultiFamily,MultipleUnit.........................................................................................................................5
Retail......................................................................................................................................................................................................5
Education...............................................................................................................................................................................................6
Commercial/Warehouse/Manufacturing...............................................................................................................................................6
Office......................................................................................................................................................................................................6
Religious.................................................................................................................................................................................................7
SecureEnvironments:FoodIndustry,Medical/LaboratoryFacilities.....................................................................................................7
JudicialandMilitary...............................................................................................................................................................................7
ProductVariations......................................................................................................................................................................................8
ManufacturingTolerances.....................................................................................................................................................................8
Color.......................................................................................................................................................................................................8
Finish......................................................................................................................................................................................................8
ThermalEfficiency..................................................................................................................................................................................8
Loadbearingvs.NonLoadbearing(Gravity)...........................................................................................................................................9
TypicalCombinations.............................................................................................................................................................................9
IndustrialGradeWall........................................................................................................................................................................9
StructuralPlus...................................................................................................................................................................................9
HighEndArchitectural......................................................................................................................................................................9
ProductTypes...........................................................................................................................................................................................10
ShearWalls..........................................................................................................................................................................................10
ColumnCover.......................................................................................................................................................................................10
Spandrels.............................................................................................................................................................................................10
Mullions...............................................................................................................................................................................................10
TrussWall.............................................................................................................................................................................................10
TrussWallAdvantages....................................................................................................................................................................10
CarbonCast.........................................................................................................................................................................................11
CarbonCastAdvantages................................................................................................................................................................11
BuildingSystemVariations.......................................................................................................................................................................11
EnvelopeSystems................................................................................................................................................................................11
LoadbearingSystems...........................................................................................................................................................................11
LateralForceResistingSystems,eitherLoadbearingorNonLoadbearing..........................................................................................12
ArchitecturalEnhancementPanels......................................................................................................................................................12
ProductSystemBenefits...........................................................................................................................................................................12
AdvantagesofanEnConPrecastWallPanelSystem...........................................................................................................................12
Precastvs.EIFS.........................................................................................................................................................................................15
TypicalDesignandDeliveryProcess.........................................................................................................................................................16
EmbeddedBrick........................................................................................................................................................................................17
AdvantagesofEmbeddedBrickoverTraditionalMasonry..................................................................................................................17
OtherBenefitsInclude.........................................................................................................................................................................17
BrickPatterns.......................................................................................................................................................................................18
BrickSizes.............................................................................................................................................................................................18
RequirementsofEmbeddedBrickUnits..............................................................................................................................................19
ConsiderationswhenChoosingEmbeddedBrickWallPanels.............................................................................................................19
FrequentlyAskedQuestions.....................................................................................................................................................................20
WhatisaSandwichPanel?..................................................................................................................................................................20
WhatisaWythe?.................................................................................................................................................................................20
WhatisaWytheTie?...........................................................................................................................................................................20
WhatareRvalues?..............................................................................................................................................................................20
WhatisaThermalBridge?...................................................................................................................................................................21
WhatistheDifferencebetweenaCompositeandNonComposite?..................................................................................................22
WhatkindofInsulationisusedinInsulatedWallPanels?...................................................................................................................22
WhyareWytheTiesandSolidZonessoImportant?...........................................................................................................................22
HowthickistheamountofInsulationinthePanels?..........................................................................................................................23

WhatsizePanelsareAvailable?..........................................................................................................................................................23
HowareWallPanelsProduced?..........................................................................................................................................................23
HowisaWallPanelSystemInstalled?................................................................................................................................................23
ArePrecastWallPanelsResistanttoAirBornDebris?........................................................................................................................24
WhataretheFinishOptions?..............................................................................................................................................................24
HowdoesBuildingwithPrecastConcreteContributetoLEEDCertification?...................................................................................25
WhatisthePCIPlantCertificationProgram?......................................................................................................................................27
CommonDetails.......................................................................................................................................................................................28
WalltoFoundation..............................................................................................................................................................................29
WalltoSlabonGradeatDockDoor....................................................................................................................................................29
ArchitecturalDetails............................................................................................................................................................................30
InsulationandBrickDetails.................................................................................................................................................................31
WallPaneltoWallPanelAlignment....................................................................................................................................................33
SpandreltoWallGravity......................................................................................................................................................................33
WallPaneltoWallPanelCorner..........................................................................................................................................................34
SteelBeamEmbedSupport.................................................................................................................................................................34
SteelJoistBearing................................................................................................................................................................................35
SteelJoistBearing(AlternativeView)..................................................................................................................................................35
SteelDeckSupport..............................................................................................................................................................................36
SteelBeamBearingPocket..................................................................................................................................................................36
DoubleTeeBearingPocket..................................................................................................................................................................37
DoubleTeeBearingwithoutPocket....................................................................................................................................................37
SamplesetofProjectSpecifications........................................................................................................................................................38
SamplesetofGeneralNotes....................................................................................................................................................................40

BenefitsoverotherConstructionMaterials
There are a variety of wall panel building systems on the market but none compare to or contain the benefits of
precast/prestressedconcrete.

EnConPrecast
TiltUp
MetalPanel
Masonry
WallSystems
DesignFlexibility

Durability

LowLifeCycleCosts

LowMaintenance

MoistureResistance

PlantProductionforQualityAssurance

ThermalEfficiency

YearRoundRapidConstruction

SecurityandSafety

ProducedUnderaPlantCertificationProgram

X
X

ProductSystemUse
Residential:SingleFamily,MultiFamily,MultipleUnit

SingleFamilyResidence

Precastwallstructuresaretheidealbuildingsystem.In
addition to their many benefits, they offer an average
reduction in heating and cooling costs of 50%. The
panelseliminateheattransfer,keepingwarmairinand
cold air out in the winter, and the opposite during the
summer months. The safety, security, and high fire
resistancepanelskeepinsurancerateslow.Wallpanels,
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
controlandprotection.

Retail
Durable and easy to care for, wall panels are perfect for public spaces. A large
TheShopsatWalnutCreek
varietyofsurfaceoptionsmake PikesPeakHarleyDavidson&Buell
precast wall panel systems especially wellsuited to retail centers
that desire a particular aesthetic appearance. The rapid
constructiontimeofawallpanelsystemminimizesinitialcostsand
enablespromptoccupancyandrevenuereturns.

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 fireresistance, precast wall panels
provideadvancedsafetyforstudentsandstaffmembersofeducationalbuildings.
FoxMeadowMiddleSchool

Commercial/Warehouse/Manufacturing
Precast wall panel systems offer high value and long life while meeting demanding
requirements.Itprovidesasmooth,hardinteriorsurfacethatresistsabrasivedamage
causedbyheavyequipment.Also,precastallowsforgreatexpansesundertheroof
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
GCCOffice,Shop&Warehouse
protects the floor from
constructiondamageandavoidsscheduledelaysduetoinclementweather.

Office

TheAerospaceCorporation

Corporate owners and managers profit from the

accelerated occupancy, insurance and tax benefits,
andreducedconstructionfinancingthataprecastwall
panel system offers. The panels are an excellent
optionforanofficeparkenvironmentasexteriorscan
be matched to those of other buildings to help new
construction blend with existing structures. This
system also accommodates the moving of walls for
thepossibilityoffuturebuildingexpansions.


Religious
Withaprecastwallsystem,amultitudeofaestheticchoices,suchascustomizeddesignsandfinishes,areavailableto
create nearly any motif. Also, insulated panels provide excellent sound reduction, events held in one space do not
disturbconcurrentactivitiesinadjacentspaces.Inaddition,precastwallpanelsofferlongtermenergyandcostsaving
benefitswithanearlymaintenancefreefaade.
EasternHillsCommunityChurch

SecureEnvironments:FoodIndustry,Medical/LaboratoryFacilities
Precast wall systems offer clean, germfree environments for facilities, such as foodprocessing plants and medical
offices,wherethisisofutmostimportance.Thisisaneconomicalandeffectivewaytomeetgovernmentstandards.
Interiorpanelsurfacescanbegivenasmoothfinishthatiseasytoclean,freeofairvoids,andresistssoiling.Inaddition,
theconcretecanbemicrobioticallytreatedtoprovideenhancedmildewresistance.Also,ledgesthatmightcollectdirt
canbeeliminated,anddurableinteriorwallsareabletoendurethecontinuedapplicationofharshchemicals.

JudicialandMilitary
Precastwallpanelsarestrongandhardwearingforanincreasedlevelofsafetyandsecurity.Theyresistrust,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 tomeet buildingrequirements. Precast insulated panels have
beentestedandshowntoexhibitexceptionalblastresistance,atypicalrequirementforthesefacilities.
FortCarsonDivisionHeadquarters

ProductVariations
Wallpanelsareversatilepiecesthatcanbeusedasarchitectural,structural,orcombinationelements.Insulatedwall
panelscanbedesignedascompositeornoncomposite,andloadbearingornonloadbearing.Inaddition,panelscanbe
castwithblockoutsforelectricalconduit,HVACductwork,windows,andentranceandegressopenings.Becauseofthe
substantialnumberofvariationsandcombinationsofpanelconfigurationsandmanufacturingtolerances,thismanual
hasprovidedyouwiththefollowinglistoffeaturesthatcanhelpwithproductselectionandspecification.

ManufacturingTolerances
There are two distinct sets of tolerances in the manufacturing of precast/prestressed concrete. These can include
dimensional,surfacefinish,andcolorvariation.TypicalstructuralgradeproductisproducedunderPCIMNL116while
architecturalproductisproducedunderPCIMNL117.ThishowevershouldnotimplythatallproductmadetoPCIMNL
116 is gray and has large variations in dimensions or all exterior faades of structures are produced to the more
stringentarchitecturalrequirementsofPCIMNL117.Anycombinationofthequalityguidelinescanbeputtogetherto
facilitatethemosteconomicalwallpanelsystemwhileensuringtheaestheticandarchitecturalintent.Asopposedtoa
paintedprecastpanel,abrickpanelwouldrequiresignificantlytightertolerances.

OurStructuralPluspanelsaremanufacturedtoPCIMNL116fordimensionaltolerancesandPCIMNL116forcolorand
surfacefinishvariation.

Color
Panelcolorisdevelopedthroughavarietyoftechniques:
ColoredPigment
ColoredAggregate
SurfaceFinishVariation
SupplementalMaterialPaintandStain

StructuralPluspanelscomeincolorsbasedonlocalaggregates,graycement,andpigment.Currently,thesecolorsare
Gray,CinnamonToast,andCream.

Finish
Panelfinishescanvaryfromaformfinish,toaverysmoothfinish,toaheavyexposed
aggregate finish. The installation of the finish is a cement or matrix removal process.
Thematerialremovalcanbeaccomplishedwithahighpressuresand,oracidandhigh
pressurewash.

ThermalEfficiency
These panels can be insulated with limited solid
zones to 100 percent thermal efficient. Typical
steadystatethermalRvaluesareontheorderof
8to15.Ifthermalmassisaccountedfor,andthe
interiorsurfaceistheconcretepanelorcontains
a single layer of gypsum, effective Rvalues 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,

levelingthepeakfluctuationsinmechanicalHVACequipmentdemand.

Loadbearingvs.NonLoadbearing(Gravity)
Forthemostefficientstructuralsystem,theexteriorwallpanelsshouldbeloadbearing.Thissolutionpreventsinterior
columns adjacent tothepanels, and eliminates the roofor floor perimeter spandrelbeams. Nonloadbearingpanels
canbereferredtoascladding,orcurtainwallsystems,andarecommonbuildingenvelopes.Theycanbeconnectedto
any type of structural frame, including precast concrete, castinplace 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
thesebearingsystemscanincludewallpanelswithorwithoutwindows,spandrels,mullions,orcolumncovers.

TypicalCombinations
IndustrialGradeWall
FoxMiddleSchool

ConcreteColor
SurfaceFinish
Insulation
Loadbearing
InlayMaterial
Liner
DimensionalTolerance
ColorandSurfaceFinishTolerance

Gray
PaintReady
Insulatedornoninsulated
Loadbearingornonloadbearing
None
None
PCIMNL116
PCIMNL116

ConcreteColor
SurfaceFinish
Insulation
Loadbearing
InlayMaterial
Liner
DimensionalTolerance
ColorandSurfaceFinishTolerance

Gray,Cream,Cinnamon
Lighttomediumsandblastfinish
Insulatedornoninsulated
Loadbearingornonloadbearing
Thinbrick,block
Thinplasticliner
PCIMNL116
PCIMNL116

ConcreteColor
SurfaceFinish
Insulation
InlayMaterial
Liner
Loadbearing
DimensionalTolerance
ColorandSurfaceFinishTolerance

Anyvarietybasedonaggregateandpigment
ExposedAggregate,sandblast,oracidetch
Insulatedornoninsulated
Stone,brick,etc.
Stone,brick,etc.
Loadbearingornonloadbearing
PCIMNL117
PCIMNL117

SandCreekHighSchool

StructuralPlus

FalconHighSchool

HighEndArchitectural

CentraliaHighSchool

ProductTypes
ShearWalls
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 nonload bearing and include both
solidandwindowpanels.

Structural panels can be loadbearing or nonloadbearing, 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 strengthand stability of a structure. Loadbearing elements include solid wall panels andcomposite
andnoncompositeinsulatedpanels,bothofwhichcancontainblockouts.

ColumnCover
Acolumncoverisaprecastpanelthatcoversoneormoresidesofacolumn.

Spandrels
Spandrelsareusedtofillthespacebetweenthetopofawindowordoorinonestory,andthesillofthewindowinthe
storyabove,oraparapet.Aspartoftheexteriorofabuilding,spandrelpanelsspanthedistancebetweenwallpanels
thatactascolumns.Thesepanelscanbeloadbearingornonloadbearing.

Mullions
Mullions are structural components that vertically divide adjacent windows and/or doors. They are nonstructural
membersanddonottypicallycarryanydeadload.Theywillgenerallyonlysupportwindloadfromthewindow/door
unit,carryingitbacktothebuildingstructure.

TrussWall
EnConalsoprovidesametaltrusswall.Thisisamediumperformanceproductthatcan
have an enhanced thermal efficiency over solid panel and panels with solid zones in
through the insulation. Prestress steel serves as primary outofplane flexural
reinforcing. A metal truss is used for reinforcing to produce composite shear transfer.
Thepanelsaredesignedasnearly100%compositeandthusrequirelessconcretethana
noncompositepanel.

TrussWallAdvantages

10

Compositeactionbetweenwythes
Lighterpanel
EdgetoedgeInsulation
Minimalthermalbridging
Minimalcondensationregions
Increaseduseablefloorarea

CarbonCast
EnCon also provides CarbonCast. This is a high performance product that can be
thermallyefficientwithcarbonfiberreinforcement.Prestresssteelservesasprimaryout
ofplaneflexuralreinforcing.Aresinbonded,carbonfibergridisusedforreinforcingto
produce composite shear transfer. Since carbon is noncorrosive and nonthermally
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
transversereinforcement,limitingtheexposureandriskofcorrosion.

CarbonCastAdvantages

Compositeactionbetweenwythes
Thinnerpanel
Lighterpanel
EdgetoedgeInsulation
Minimaltonothermalbridging
MinimaltonoCondensationregions
Thermallynonconductivewytheconnections
Increaseduseablefloorarea

BuildingSystemVariations
EnvelopeSystems
Architecturalornonloadbearingpanels,oftenreferredtoascladdingorcurtainwalls,are
the most common use of precast for building envelopes. They can be connected to any
type of structural frame, including precast concrete, castinplace concrete, or steel.
Architectural wall panels enclose a space and do not transfer vertical loads. They are
typicallydesignedtoresistwindandseismicforcesgeneratedbytheirownweight.These
precastpiecescanincludewallpanelswithorwithoutwindows,spandrels,mullions,and
columncovers.

CECProject

LoadbearingSystems
Loadbearingpanelsarestructuralcomponentsthattransfergravitational
orverticalloadsfromotherelementsandcontributetothestrengthand
stability of a structure. Loadbearing elements include solid wall panels
andcomposite and noncomposite insulated panels,both of whichcan
containblockouts.

11

LateralForceResistingSystems,eitherLoadbearingorNonLoadbearing
Shearwallsarealsostructuralcomponentsandfunctionaspartof
thelateralresistancesystemofabuilding,withstandingforcesfrom
wind, blast, or earthquake. They can be loadbearing or non
loadbearingandincludebothsolidandwindowpanels.

UniversityofColoradoatColoradoSpringsDorms

ArchitecturalEnhancementPanels

Architecturalwallpanelscanbeusedtoenhancethe
appearance of multiple construction applications.
Integrated with steel, stone, masonry, or even cast
inplaceconcrete, highly detailed and ornate panels
candramaticallyimprovetheexteriorofastructure.
Personalized emblems, symbols, or logos add
additionalvisualinterest.

FolsomFieldAddition

ProductSystemBenefits
Precastconcretewallpanelsystemshavedemonstratedhighvalueandversatilityineverymarket.Noothermaterialor
systemcombinesasmanybenefitsasaprecastwallsystem.

AdvantagesofanEnConPrecastWallPanelSystem
TheEnConCompanieshavedeliveredhighqualityprecastconcretestructuresthroughouttheUnitedStates,andholda
strong commitment to partnership, customer care, and product excellence. From design support to product
installation,theymaintainafullservice,integratedapproachtodelivery.Asaresult,clientsreceivethebenefitsand
convenienceofasinglesourcesupplier.Thishelpslimittheprojectrisk,aswellasthenumberofsubcontractsneeded.

DesignFlexibility
Precastwallpanelscanbeproducedindifferentsizesanddepths,offeringmoredesignflexibilitythanother
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.Speciallyconstructedformsallowforthecastingofcurvedorradiusedpanelstocreateuniquely
shapedbuildings.Panelscanbecastwithblockoutsforwindows,ductwork,andelectrical,aswellasentrance
andegressopenings.Panelscanalsobefabricatedwithpreinstalledwindowsandstudnailersappliedatthe
plant.Theentirepanelcanthenbeliftedintoplacewithminimumpreparation.

12

AestheticallyVersatileExteriors
Precast is an extremely adaptable material and offers unlimited aesthetic options. Exterior surfaces can be
finishedtocomplementthesurroundinglandscapeaswellasmatchthedesignofanexistingstructure.Precast
easilyaccommodatestheuseofotherbuildingmaterialstocreateacohesiveappearance.Uniqueandintricate
personalizeddesignscanbecastintothepanelsusingformliners.Thismakesiteasytoadddetailssuchas

revealpatterns,names,emblems,andsymbols.Multicolorpainttreatmentscanfurtherhighlightarchitectural
features.Panelscanbeproducedinoneormultiplecolors,andalsoinavarietyoftexturesandaggregates.A
varietyofsurfacingtechniquesmayalsobeappliedtothepanels.Theseincludesandblast,acidetch,trowel,
polishing,stain,andpaint.Theresultscanincludeasmooth,ribbed,orexposedaggregatefinish.Theycanalso
replicate the appearance of wooden boards. Furthermore, panels can also be clad in brick, tile, terra cotta,
limestone,sandstone,granite,marble,orstone.

InteriorSurfaces
Panelscreateadoublewallsystemwheretheinteriorwallsareessentiallyprefinished,eliminatingtheneedfor
andexpenseofadditionalsurfacetreatments,includingdrywall.Awidevarietyoffinishes,includingpaint,can
beappliedtothepanelsifdesired.Intermediatebracingisnotneeded,aspanelstypicallyofferclearheightsof
30ftcreatingunobstructeduseofthefullinteriorheightofthebuilding.

Economical
EnConsprecastwallpanelsareanexcellentbudgetconsciouschoicethatdoesnotsacrificehighquality.Wall
panelsystemsarecostcompetitivewithothersystemsthatdonotofferthebenefitsofprecast.Fabricationon
a permanent long line facility allows for more panels to be cast simultaneously, resulting in decreased labor
costsandanacceleratedprojectschedule.Precastwallsystemsfacilitatebuildingexpansions,whichhelpkeep
futureconstructioncoststoaminimum.

ExpeditedConstructionSchedule
Wallpanelsystemscanbecastatthemanufacturingfacilitysimultaneouslywithjobsitepreparationandthere
isnoneedtocasttheinteriorslabbeforepanelerection.Thus,installationcanbeginimmediatelyfollowing
delivery.Inaddition,theavailabilityoflargepanelsizesmeansfewerpanelstobecastanderected.EnCons
wallpanelsandsystemscanbefabricatedanderectedininclementweatherconditionsandinenvironments
thatwouldotherwiseinterferewithbuildingconstruction.Finishedinteriorwallsalsoeliminatethetimeand
expenseoffurringstripsanddrywall.

GreenConstruction
Sustainable, thermally efficient, and having low life cycle costs, a precast wall system is an excellent building
solution in todays environmentallyconscious climate. Plant fabrication results in reduced construction time and
lessjobsitewasteandcongestion,allofwhichhavelessofanimpactonthelandscape.Unlikeotherbuildingand
framingmaterials,precastconcretedoesnotreleasetoxinswhenburned.Concreteprovidesthermalmass,which
delaysheattransferthroughbuildingwallsandmoderatesindoortemperaturefluctuationsasoutdoortemperature
varies. Along with lowering heating and cooling costs, this helps to meet stricter energy requirements. With
integral insulation,highperformance sandwich panels further reduce energy consumption, forgoing theneed for
extrainsulation.TypicalRvaluescanrangefrom8tomorethan18.

HighQuality
Plant casting yields a more predictable product with greater quality control, consistency, and finish. With focus
placedonultimatestrengthratherthancuretimeandtemperature,precastwallpanelsarestrongerthanconcrete
blocksorwallsthatarecastonsiteandtiltedintoplace.Prestressingreinforcementyieldsinherentstructuraland
serviceabilityadvantages,suchasincreasedstrength,ductility,crackcontrol,andpanelflatness.

SafetyandSecurity
Precastconcreteisnaturallyfireresistantwhilewallpanelsystemsinhibitfirespread.Thishelpstoensureablaze
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.Foamblockoutsareusedtoaccommodateplumbing,mechanical,andelectricalpenetrations.This
minimizes the amount of onsite core drilling and decreases jobsite risk. Precast concretes structural stability
providesresistancetodamagecausedbyforcesofnaturethatincludingseismicevents.Wallpanelscanbetreated
andfinishedtocreatearoomfreeofdust,particles,andothercontaminants.Thesecharacteristicsareofparticular
importancetohealthcareandresearchfacilities.

13

MoistureResistanceandAcousticalControl
Fabricatedwithalowwatertocementratio,highlydenseprecastconcreteinhibitswaterpenetration.Precastwall
panelseliminatetheneedfordrywall,supplyinganaddedmeasureofprotectionagainstmoldandmildewgrowth.
Panels,especiallyinsulatedpanels,diminishnoisetransmissionforgreaterprivacyandreducesoundtransmission
fromoutsideabuildingtotheinside.

LoadbearingvsNonLoadbearing
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
specialbuiltinbeamfeatureatthebaseofapanelenablesittospanfromcaissontocaisson.

14

FireResistance
FireratingsarebasedonaRationalFireDesigncalculationmethodoranIBCPrescriptiveFireRatingmethod.Afire
ratingisdependentuponequivalentthickness,heattransmissionthickness,coverontheprestressingstrand,and
endrestraint.Astandard8in.thickHollowCoresystemhasatwohourfirerating.However,higherratings(three
or four hour) may be achieved with topping and gypsum board, or the application or a sprayon, fireresistant
materialtotheundersideoftheslab.

BlastResistance
Insulatedwallpanelshavebeenshowntoholdsuperiorstrengthsandenergyabsorptioncharacteristics.Thishas
been revealed through recent, full scale testing and blast simulations with end results that place precast wall
systemshighabovetraditionalbuildingmethods.


Precastvs.EIFS
EnConsprecastproductsstanduptootheroptionswithintheindustryasthepremierbuildingsystem.

ThequalityofEnConsInsulatedPrecastConcreteProductsisunsurpassedaseachpieceisengineeredagainstcracking
underallserviceconditions.Theirproductsarepredominantlyusedfortheexteriorbuildingenvelopeandaredesigned
to prevent moisture infiltration into the structure, for the life of the
structure.Inaddition,manyoftheproductsareprestressed,areinforcing
technique developed to increase span, capacity, and decrease the
propensity for cracking. Because of the high standards placed on the
precastdesignandmanufacturingprocess,itisamoredurableandefficient
choicethanitscounterpartswithintheindustry.

InsulatedConcreteWallPanel

EIFS, an alternative to precast, is a finishing technique in which crementitious top and base coats are applied to
ExpandedPolystyreneInsulation.Theinsulationisthenapplieddirectlytothestructuredsheetingeitherthroughglue
or mechanical fasteners. Due to this method of construction, the finished exterior can be somewhat soft and
susceptibletocracking,indentations,andpenetrations,damagingthefinishedsurface.Inturn,waterinfiltrationand
moldbecomecommonproblems.

AnotherformofEIFSconsistsofapremanufacturedpanelofinsulationwithastructuralmetalframecoatedinathin
baseandfinishcoat.Althoughthisisasimilarconcepttothatofaprecastpanel,theEIFSPanelsystemistypicallynot
engineered for rigidity or to prevent surface cracks. The latest EIFS system designs have included a vapor barrier
between the insulation and
sheathing.Althoughthisprovides
better moisture control in the
field, portions of the insulation
and mechanical fasteners still
penetrate this membrane and
create a potential source of
moistureintrusion.

TypicalEIFSCrossSection

15


TypicalDesignandDeliveryProcess
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.
Thereareanumberofinterrelatedyetoverlappingactivitiesthatallowfasterturnaroundandquickerjobcompletion.

Project
Identification

Preliminary
Design
Assistance

Estimate and
Award Project

Final Design

Calculations,
Erection Drawings,
and Details

Submittal
and Approval
Process

Manufacture, Store,
and Transport

Erection and
Field Finish

Project
Completion

16

Final Erection
and Production
Drawings

EmbeddedBrick
Whenthinbrickiscastintoconcretewallpanels,thisproducesembeddedbrick;amaterialthatcanbeimplementedto
createanentirestructureaswellasdecorativeelementsonabuildingfaade.

RoseMedicalCenter

AdvantagesofEmbeddedBrickoverTraditionalMasonry
Along with aesthetic appeal and low cost, there are numerous benefits surrounding brickembedded concrete over
conventionalmasonry.Theseincludenolintels,flashing,weepcavities,airspace,waterproofing,orefflorescence.In
addition,thereisnotimeconsuming,onsiteconstructionofmasonryproducts.

OtherBenefitsInclude:

Pleasingtraditionalappearanceofbrick,whileleveraging
thestrength,speed,andeconomyofprecastconcrete
Duetolowabsorptionrates,thinbrickisratednotto
effloresce
Inlaidthinbrickwallsrequirednoperiodicsealingortuck
pointingrepair
ThinbrickprecastconformstoPCIstandardsforbrick
embeddedinprecast

SplitfaceInlay

17

Forthoseseekingabrickfinishthatisbothvisuallyappealingandeconomical,EnConoffersthinbrickwallpanelsthat
comewithvariousoptionsincludingarangeoffinishes,sizes,andshapesofbrick.Therearealsopiecesthatareusedto
createarchitecturalcorners,arches,soldiercourses,andothertraditionalbrickpatterns.

BrickPatterns

RunningBond

FlemishBond

SoldierCourse

StackBond

NumerousBondingPatterns

Arches

BrickSizes

EnglishBond

OrnateCorbels

ModularBrick

NormanBrick

18

UtilityBrick

BrickCorner
EdgeCap


RequirementsofEmbeddedBrickUnits

Havedimensionaltolerances+0in.1/16in.onallunits8in.orunder;+0in.3/32in.onallunitslargerthan8
in.
Havea24hourcoldwaterabsorptionratenormorethan6%whentestedperASTMC67
Maintainaconsistentplaneof+0in.1/16in.(+01.6mm)
AllShapesshallconfirmtothearchitectsspecifiedanglewithatoleranceof1(MeasuredperASTM
C67)
Maintainanoutofsquaredimension1/16in.(1.6mm).MeasureperASTMC67
RatenotefflorescedperASTMC67
Exhibitminimumtensilebondstrengthor150psi(1.0MPA)whentestedperASTMC482
Exhibitnodetectabledeterioration(spalling,cracking,chafing,etc.)whentestedinaccordancewithASTM
C666MethodB,modifiedtowithstand300cycles
Beshowntodemonstrateminimumofmodulesofruptureor250psiper(1.7MPA)whentestedinaccordance
toASTMC67
RatenotaffectedbychemicalattackwhentestedperASTMC650

ConsiderationswhenChoosingEmbeddedBrickWallPanels
Anumberofthingsshouldbeconsideredduringthedesignanddetailingofeachspecificproject.Theseincludebrick
andpanelsizesandshapes,loadbearingconditions,panelopenings,andbrickpaneltolerances.

Modularbricksizesshouldbeusedwhendeterminingpanelwidths,heights,andopenings.
Theuseofconcretebandingattheedgesofprecastpanelsandopeningsshouldbeconsidered.Bandingcan
minimizethecostofhavingtocutbricktooddsizes,ortheneedtobuildpanelstosizesthatonlyfitthe
moduleofthebrick.Bandinghelpswiththisbycreatingasolidconcretefacealongapaneledgetowhichthe
brickissetagainst.Itcanalsobeusedtodifferentiatefloorlocations,paneljoints,andotherarchitectural
effects.Bandingalsopermitspanelheights,widths,andopeningsizestobenearlyanydimension,
independentofbrickcoursing.
Itisvitalthatmasonrycoursingbecontinuousfrompaneltopanel,bothverticallyandhorizontally.Thisis
importantwhenconcretebandingisnotusedattheedgeofpanels.
Whenaformlinerpatternthatisrectilinearormodularisused,aligningthebrickpatternwiththeconcrete
patternshouldbeconsidered.Thiswillhelptoalignopeningsinthedifferentpatterns,aswellascreateawell
ordered,visuallypleasingfaade.
Whenusingconcretebandingatjambsofwindowordooropenings,in.istheminimumrecommended
concretejambbandwidth.
Precastheaderandsillheightsandlengthsshouldbeplacedsymmetricallywithinthebrickmodularpattern.
Cornerbrickcanbeusedforbothpanelendsandbrickreturnsatwindowanddoorheadsandjambs.Opening
sizesshouldfitsymmetricallywithinthebrickmodule.Pleasenotethatcreatingopeningsizestofitthebrick
modulemayrequireorderingcustomsizewindows.
Althoughitismorecostlythanusingstandardmodularsizes,cuttingbricktospecialsizesatedgesofpanels
andpanelopeningscanbeachievedifnecessary.Ifaspecialsizeopeningisrequired,theopeningshouldbe
locatedsothatthebrickiscutequallyoneithersideoftheopening.
Industrystandardmanufacturingtolerancesofbothprecastpanelsshouldbeconsideredduringthedesignof
eachproject.
Tolerancesthatshouldbetakenintoconsiderationincludefloortofloorheights,panelheights,brickcoursing,
jointsizes,loadbearingconditions,andjointdetails.

19


FrequentlyAskedQuestions
The following section relates to typical questions regarding wall panels, specific terms and properties, and the
manufacturinganderectionprocess.

WhatisaSandwichPanel?
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.

WhatisaWythe?
Awytheisalayerwithin,oronthesurfaceofasandwichpanelorinsulatedwall
Panel.

WhatisaWytheTie?
A Wythe Tie is the name of the material that connects two or more layers of
concrete(wythes)togetherinaninsulatedwallpanel.

WhatareRvalues?
Rvalue, or Thermal Resistance, is one measurement of
FactorsthatImpacttheThermal
the thermal performance of a system. There are two
PerformanceofaStructure
Effectsof
typesofRvaluesdiscussedintheconstructionindustry.
Daily
Analysis
SteadyState
These are Steady State Rvalues and Effective Rvalues.
Temperature Duration
RValue
Range
The Steady State Rvalue is traditionally based on the
Thermal
Shorts
measured, one dimensional resistances of the
Humidity
construction materials that comprise the system for a
Geographic
AirInfiltration
givenassemblyofmaterials.
Position

FloorSystem
AlthoughthereareanumberoffactorsthatinfluenceR
Foundation
values, the Effective Rvalue is primarily a combination
Conectivity
ThermalMass
ofSteadyStateRvalueandThermalMass.

There are no standard methods of calculating Effective Rvalues. One method, however, is the development of a
multiplierformasswallsystemsortheDynamicBenefitforMassiveSystems(DBMS).ThismultiplierrelatestheSteady
State Rvalues to Effective Rvalues using a standardized lightweight wood frame structure as a base line. The
standardizedhomeismodeledwitheachwallsysteminordertodeterminethetotalbuildingenergyloadforagiven
durationandclimate.

The Steady State Rvalue of the exterior wall system for the standardized lightweight wood framed home is then
manipulateduntiltheenergyloadsarethesameasthemasswallsysteminquestion.TheratiooftheSteadyStateR
valueofthemodifiedwoodstructuretotheSteadyStateRvalueofthemasswallsystemisequaltotheDBMS.One
benefitofthisapproachisthatitallowsfortheevaluationofsimilarmasswallconstructiontechniques,wallassemblies
ofsandwichedinsulation,andwallassembliesofsandwichedconcrete.

TheindustrystandardforthermalperformancecomparisonshouldbeacomparisonofSteadyStateRvalues.
ThismethodisanexcellentpredictorofRvalueswithvariationsinmaterialthickness,solidzones,orthermalshorts.It
has been adopted by the Precast and Prestressed Concrete Institute Design Handbook as the preferred method of
calculatingRvaluesforcomplexassemblies.

20


WhatisaThermalBridge?
The inner and outer concrete thicknesses
ofatypicalprecastinsulatedwallpanelare
calledwythes,andareconnectedtogether
withwytheties.Thesetiescanbemadeof
steel, carbon fiber, or solid zones of
concrete.Itistheintentofmostdesigners
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
whichheatistransferredatasubstantially
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
metalfastenerorconcretebeam.

TemperatureResults
Athermalbridgeiscreatedwhenmaterialsthatarepoorinsulatorscomein
12in.BrickandBlockWall
contact,allowingheattoflowthroughthepaththatisgenerated.Because
ofthermalbridging,insulationaroundabridgeisoflittlehelpinpreventing
heatlossorgain.

TemperatureScale

Typicaleffectsofthermalbridges
Surface moisture due to condensation, may occur in such
include:
regionsasfloortowallconnections,windowinstallations,etc.,
as well as mold growth in humid environments can also be
Decreasedinteriorsurface
effectivelypreventedbymeansofmultidimensionalevaluation
temperatures;intheworstcases
during planning and detail design. Concrete balconies that
thiscanresultincondensation
extendthefloorslabthroughthebuildingenvelopearealsoa
problems,particularlyatcorners
commonexampleofthermalbridging.
Significantlyincreasedheatlosses

Coldareasinbuildings.

BrickTieImage

BrickTieThermalImage

21

WhatistheDifferencebetweenaCompositeandNonComposite?
A panel is classified by the amout of composite action it has, or the amount of
interactionbetweenthetwolayersofconcreteitholds.Themorecompositeactiona
panel has, the more the two layers act together, and the stiffer the panel. The less
compositeaction,themoreeachlayeractsindependent,andthelessstiffthepanel.
Compositewallpanelsareinsulatedsandwichpanelswithwythesthatactasasingle
unitunderloadbearingandnonloadbearingconditions.Compositeshearconnectors,
orcompositewytheties,enablethemembertoactasonesingleunitwiththesame
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
thesameapplicationasasolidpanel.Sincetheinnerconcretewytheisthinnerthere
ismoreusableinteriorspace.Noncompositepanelscontainconnectorsorwytheties
thatallowtheconcretelayerstoactindependently.Thesepanelsaretypicallyheavier
thancompositepanelsandmustbethickertoperformthesamestructuraltasks.

WhatkindofInsulationisusedinInsulatedWallPanels?
Insulatedpanelscontaintwowythesofprecastconcreteandaninteriorcoreoffoaminsulation.TheinsulatingfoamR
valuesaretwotothreetimesgreaterthanmostotherinsulatingmaterialsofthesamethickness,suchasfiberglassor
cellulose.Therearetwoprimarytypesofinsulation.Theseareexpandedpolystyrenefoamandextrudedpolystyrene
foam.Expandedpolystyrenefoam(EPS),commonlyknownasbeadboard,isaclosedcellfoamboardcontainingsmall
beadsofpolystyrenewhichareexpandedbyheat.EPShasatypicaldensityof1to2poundsandofferslongtermR
value, strength, stability, and water resistance. Extruded polystyrene foam (XPS), also a closedcell material, is
comprisedofpolystyrenethatischemicallyliquefiedandforcedthroughashapingdie.

WhyareWytheTiesandSolidZonessoImportant?
Nomatterhowmuchinsulationisinasystem,certainwythetiemethods,suchasmetalandsolidzones,createthermal
bridges that dramatically reduce the insulations effectiveness. These thermal shorts create cold spots that may
producecondensationwhichcouldpotentiallydevelopintootherproblems.

Material
Rvalue1

TestRvalue1

PercentLoss

Panelwithsteelwytheties

10.48

7.55

27.96%

Panelwithsolidzones

10.48

5.77

44.94%

Panelwithsolidzonesandsteelwytheties

10.48

4.56

56.58%

PanelwithlowthermalconductivityFRPconnections

10.48

10.57

0.86%

PanelDescription
323panelsmadewithextrudedpolystyrene

1.

ValueobtainedsummingRvaluesforconcreteandinsulationlayers,noairfilmsincluded.Source:SummaryofThermal
TestsofInsulatedConcreteSandwichWallsU.S.Dept.ofEnergy19981999.

Nearly allbrick and block systems containmetal tiles to laterally support the exterior brick
face.Thecoldspots,producedbythesethermalshorts,increasethepassageoftheexterior
environment to the interior environment creating an increase in the interiors heating and
coolingdemand.

22

HowthickistheamountofInsulationinthePanels?
Thetypicalthicknessis2in.However,thisisnormallyaminimum.DependingupontherequiredRvalue,insulation
thicknesscanreachupto6in.

Expanded
Polystyrene
(EPS)

InsulationThickness

Rvalue*

Extruded
Polystyrene
(XPS)

2inches

10

4inches

16

20

6inches

24

30

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

WhatSizePanelsareAvailable?
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
extendoverseveralfloorsinheightwithapreferredmaximumheightof50ft0in.

HowareWallPanelsProduced?
Precastpanelsareformedbyplacingconcreteintoaseriesofmoldsorforms.

FormingandSetup

ConcretePlacement

FinishedSurfacePreparation

ProductStorage

HowisaWallPanelSystemInstalled?
Wallpanelsshouldbeinstalledbyskilledtechnicianswithexperienceinerectingprecastconcrete.Thepanelsaretobe
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
startingposition,aswellastheresultsofasitesurveytoensureproperelevationsandbuildinggeometrybeforethe
startoferection.

Transporting

Tripping
RotatingtoVertical

Placement

23

ArePrecastPanelsResistanttoAirBornDebris?
ThefollowingpictureshavebeencapturedfromavideocourtesyofThePrecastConcreteInstitute,PortlandCement
Association,andPCAandDukanePrecastInc.Theprojectile,awood2x4,wasdeliveredfroma100mphaircannon
intoathinbrickinsulatedprecastsandwichpanelandatraditionalsteelbrickfacecommercialwallsystem.Thereisno
signofprojectilepenetrationintheprecastwallpanel,whilethetraditionalcommercialsystemclearlyshowssignsof
penetrationintothespaceoftheinteriorofthestructure.

ThinBrickInsulatedPrecastSandwichWallPanel

TraditionalCommercialConstruction:BrickVeneerwith2x6SteelStudFraming

WhataretheFinishOptions?
From a simple paint treatment to a more complex acidetch
technique, EnCon has a finish to fit every budget. When the
concreteispouredintoahorizontalbed,thebottom,orformside
ofthepanel,isusuallytheexteriorfaade,whilethetopservesas
theinteriorwall.Thiscreatesadoublewallsystem.

Interior surfaces can range from a singlepass Fresno to a multi

passtrowel.Paintorstainmayalsobeappliedtocoordinatewith
anycolorscheme.

24

Exterior finishes include paint and stain applications, acidetch,

exposed aggregate, sandblast, and a countless number of
patternsshapedwithformliners.

Painttreatmentappliedto
GrayInsulatedWallPanels

AcidEtch

ExposedAggregate

Sandblasted

ExposedAggregate/AcidEtch

Brick

Reveals

Stone

WoodenBoards

HowdoesBuildingwithPrecastConcreteContributetoLEEDCertification?
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
overthelifeofthestructure,havelessnegativeimpactonthesurroundingecology,
aswellasincreasethelifeofabuilding.

Precastisthemostwidelyusedbuildingmaterialandhasmanyattributesthatmakeit
morepreferablethancastinplaceconcreteandothertraditionalbuildingsystems.

Theuseofprecastislessdestructivetothenaturalenvironment:
1. Plant casting reduces the resources needed for onsite formwork and
decreaseswastegeneratedattheconstructionsite.
2. As precast components are installed more quickly, construction time is faster with less onsite congestion,
noise,andemissionsfromequipment.
3. Lessmaterialisrequiredtoachieveloadbearingcapacitysimilartothatofotherbuildingsystems.

Precastconcreteconservesbothresourcesandmaterials:
1. Precastcontainsrecycledmaterialsthatwouldotherwisegotolandfills.Byproductsofotherindustries,such
asflyash,slag,andsilicafumecanbeincorporatedintoconcrete.Thesesupplementarymaterialsenhancethe
performanceofprecastandalsoreducetheamountofcementthatisusedinconcrete.
2. Precastpiecescanberecycledandmayberearrangedorremovedtoaccommodatebuildingadditions.They
canalsobereusedinotherapplications.
3. Concreteitselfcanberecycledasfillorroadbaseandcanbereusedtoprotectshorelines.
4. Mostreinforcingbarsaremanufacturedfromrecycledsteel.

25

5.

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

Precast concretes inherent thermal mass and heatstorage capacity offer major advantages to maximize energy
performance.Insulatedwallpanelsprovideevengreaterthermalefficiency.

FortCarsonBrigadeandBattalionHeadquarters
FirstLEEDGoldCertifiedbuildingintheMilitary

FalconHighSchool

SeekingLEEDCertificationSilver

26


WhatisthePCIPlantCertificationProgram?
PCIsPlantCertificationProgramensuresthateachplanthasdevelopedanddocumentedanindepth,inhousequality
systembasedontimetested,nationalindustrystandards.PCICertifiedplantsareauditedinaccordancewithstandards
publishedinthreePCIqualitycontrolmanuals(MNL116,MNL117,andMNL130).Precastingplantscanbecertifiedin
asmanyasfourproductgroups:
GroupAArchitecturalProducts
GroupBandBABridgeProducts
GroupCandCACommercial(Structural)Products

PCI'splantcertificationprogramascomparedtothoseofferedbytheNationalPrecastConcreteAssociation
(NPCA)andtheArchitecturalPrecastAssociation(APA):
Criterion

PCI

Structuralproducts
(prestressed)established5
yearsormore

Precastconcreteproduct
(conventionalreinforcement)

Architecturalprecastconcrete

P.E.inspection/oversight

Allinspectionsunannounced

NPCA

APA

Comment
Established,provenexperiencedemandedbytheconstructionindustry.High
structuralcapacity,longtermdurability,andserviceabilityofbothconventionally
reinforcedandprestressedconcreteproducts,allofwhicharedirectlyinfluenced
bythemanufacturersqualityandproductionoperations.Prestressingoperations
areperformedbyproperlytrainedplantpersonnelsupervisedbycertifiedquality
controlpersonnel.
Highqualitymanufacturingofconventionallyreinforcedproducts,whichareoften
nonstructuralandnonarchitecturalinnature.

X
X

Morestringenttoleranceandappearancerequirementsforarchitecturalprecast
concreteproductsthanforconventionalorstructuralprecastconcreteproducts.
Architecturalprecastconcreteproductsthatnotonlylookgood,butare
manufacturedtomaximizelongtermdurabilityanddesiredfunction.

Verifiableproof,providedbyprofessionalengineeringregistration,ofaminimum
levelofcompetence,experience,andeducation.

Amoreaccuratemeasureofaplantsroutinecompliancewithrequiredquality
operationsandmanufacturingpractices,leadingplantstomaintainconstant
vigilanceandastrongfocusonquality.

Minimum2inspectionsper
year

Ongoingcompliancewithqualityandmanufacturingrequirements.Aplantquality
systemthatincorporatesthelatesttechniquesandisoperatingproperlyona
regularbasis.

ApprovalofplantQCmanual

Reviewandapprovalofaplantsinternalqualitymanualpriortoconductingan
audittoverifythataplanthasaddressedallofthecriticalfactorsthroughoutthe
qualitysystem.Aqualitymanualthatclearlyaddresseseachproductgroupand
categorythattheplantmanufactures.

MandatoryforPCI
ProducerMembers

Mandatoryparticipationformembers,whichindicatesthatanorganizationtruly
believesinandsupportsqualityintheindustry.Allmembersplantsareoperated
withestablishedprocessesandprofessionalismbecausetheirorganizationrequires
certificationasaprerequisiteformembership.

Personnelcertification

Properlytrainedplantpersonnel,whoarecriticaltoensuringproductionofhigh
qualityprecastconcreteproducts.Verifiableproofofproperpersonneltraining,
whichcreatesapositivecredentialthatcanbeusedinjobadvancement.Expiration
datesforpersonneltrainingandcertification,requiringperiodicrecertificationwith
verificationofqualificationsandcompetenceassessments.

Fieldcertification

Extensionofthedemandingqualitystandardsrequiredwithplantcertificationto
theprocessoferectingthefinishedprecastconcretecomponentsatthesite.
Erectiontonationallyrecognizedstandards.

Qualitycontrol(QC)manuals

Exposuretodetailedandcomprehensivequalitycontrolmanualsthatprovidethe
basisforproperpersonneltrainingandeachplantsmanufacturingandquality
operations,withspecificinformationtoensureuniforminterpretationofboth
requirementsandsupplementalcommentary.

2008Precast/PrestressedConcreteInstitute

27

CommonDetails
Thedetailsonthefollowingpagesarenoncrosssectionspecificandareapplicableinstandardloadbearingandnon
loadbearingconditions.Inaddition,theycanbeusedasgenericdetailsforinsulatedpanels.Althoughthesearenotthe
onlydesignoptionsavailable,theyareoftenusedasstartingpointsforjobspecificsectionsanddetailrequirements.
Connection details will vary slightlydepending on whether the slab was produced usinga drycastextrusion ora slip
form technique. Designers are strongly encouraged to discuss potential details with the fabricator during design
development.

28

WalltoFoundation

WalltoSlabonGradeatDockDoor

29

ArchitecturalDetails

30

InsulationandBrickDetails

31

InsulationandBrickDetails

32

WallPaneltoWallPanelAlignment

SpandreltoWallGravity

33

WallPaneltoWallPanelCorner

SteelBeamEmbedSupport

34

SteelJoistBearing

SteelJoistBearing(AlternativeView)

35

SteelDeckSupport

SteelBeamBearingPocket

Note:
Thisdetailcannotoccurat
eachendofthesameTee.

36

DoubleTeeBearingPocket

Note:
Thisdetailcannotoccurat
eachendofthesameTee.

DoubleTeeBearingwithoutPocket

37

SamplesetofProjectSpecifications
1.01

1.02

1.03

SECTIONINCLUDES
A. Structural,ArchitecturalandInsulatedwallpanels,relatedconnectionplates,brackets,hangers,andgroutingofhorizontaljoints.

RELATEDSECTION
A. Section03410StructuralPrecastConcrete,StructuralPrecastConcretewithCommercialArchitecturalFinish
B. Section03450ArchitecturalPrecastConcrete
REFERENCES
A. ACI301StructuralConcreteforBuildings.
B. ACI318BuildingCodeRequirementsforStructuralConcrete.
C. ASTMA36StructuralSteel.
D. ASTMA153ZincCoatingonIronandSteelHardware.
E. ASTMA416UncoatedSevenWireStressRelievedSteelStrandforPrestressedConcrete.
F. ASTMA615DeformedandPlainBilletSteelBarsforConcreteReinforcement.
G. ASTMA666AusteniticStainlessSteel,Sheet,Strip,Plate,andFlatBarforStructuralApplications.
H. ASTMC150Portlandcement.
I.
ASTMC618FlyAsh.
J. ASTMC33Aggregates.
K. ASTMC260AirEntrainmentAdmixtures.
L. ASTMC494WaterReducingAgents.
M. AWSD1.1StructuralWeldingCode.
N. AWSD1.4StructuralWeldingCodeReinforcingSteel.
O. PCIManualForTheDesignofHollowCoreSlabs.
P. PCIMNL116PCIStructuralQualityControlManual.
Q. PCIMNL117PCIArchitecturalQualityControlManual.
R. PCIMNL120PCIDesignHandbook.
S. PCIMNL123PCIConnectionsManual.
T. PCIMNL124PCIDesignforFireResistanceofPrecastPrestressedConcrete.
U. PCIMNL127PCIErectionTolerances.
V. PCIMNL135TolerancesforPrecastandPrestressedConcrete.
W. IBCInternationalBuildingCode.

1.04

DESIGNREQUIREMENTS
A. Sizecomponentstowithstanddesignloads.
B. Concrete:Minimumcompressivestrengthof5000psiat28daysand2500psiatrelease.
C. Designcomponentstoaccommodateconstructiontolerances,deflectionofotherbuildingstructuralmembersandclearancesof
intendedopenings.
D. Grout and connections at joints to resist lateral and gravity loads or the structure. Calculate structural properties of framing
membersinaccordancewithACI318.

1.05

SUBMITTALS
A. Shop Drawings: Indicate wall locations, unit identification marks, connection details, edge conditions, bearing requirements,
supportconditions,dimensions,openings,openingsintendedtobefieldcut,andrelationshiptoadjacentmaterials.
B. ProductData:Indicatestandardcomponentconfigurationanddesignloads.
C. FabricatorsInstallationInstructions:Indicatespecialproceduresandconditionsrequiringspecialattention.

1.06

QUALITYASSURANCE
A. PerformworkinaccordancewiththerequirementsofPCIMNL116orPCIMNL117_,PCIMNL123,andPCIMNL120.
B. Maintainplantrecordsandqualitycontrolprogramduringproductionofprecastwalls.Recordsavailableuponrequest.

1.07

QUALIFICATIONS
A. Fabricator:CompanyspecializinginmanufacturingtheworkofthissectionandPCIcertified.
B. Erector:Companyspecializinginerectingtheworkisrecommended.
C. DesignprecastconcretemembersinaccordancewithMNL120PCIDesignHandbookPrestressedandPrecastConcrete,under
directsupervisionofaProfessionalEngineerexperiencedindesignofthisworkandlicensedinthestateoftheproject.
D. Welder:QualifiedinaccordancewithAWSD1.1.

1.08

38

REGULATORYREQUIREMENTS

A.
B.

1.09

ConformtoACI318codefordesignloadandonsiteconstructionrequirements.
ConformtoPCIMNL124,PCIMNL116or117forarchitectural,.

PREINSTALLATIONCONFERENCE
A. Discussanchorandweldplatelocations,sleevelocations,andcautionsregardingcuttingorcoredrilling.

1.10

DELIVERY,STORAGE,ANDHANDLING
A. LiftingorHandlingDevices:Capableofsupportingmemberinpositionsanticipatedduringmanufacture,storage,transportation,
anderection.
B. Markeachmemberwithproductionidentificationandorientation(ifrequired.)

1.12

COORDINATION
A. Coordinateworkunderprovisionsofseparatesection.

2.01

2.02

FABRICATORSPCICertifiedPlant
MATERIALS
A. Materials:TobeinconformancewithACI318.
B. TensioningSteelTendons:ASTMA416Grade270.
C. ReinforcingSteel:ASTMA615orA706,deformedsteelbars.
D. SandCementGrout:Sufficientforplacementandhydration.

2.03

ACCESSORIES
A. ConnectingandSupportingDevices:ConformtoPCIMNL120plates,angles,itemscastintoconcrete,itemsconnectedtosteel
framingmembers,andinserts;ASTMA36carbonsteel.
B. Steelshimsasrequiredbydesign

2.04

FABRICATION
A. ConformtoAWSD1.4andPCIMNL116or117forarchitectural.
B. Embedanchors,inserts,plates,angles,andotheritemsatlocationsindicated.
C. Provideopeningsrequiredbyothersectionsatlocationsindicated.Greaterthan12inchessquareorindiameter.

2.05

COMPONENTS
A. NominalThickness:Asrequiredbytheproject
B. NominalWidth:Asrequiredbytheproject

2.06

FINISHES
A. PlantFinish:FinishmemberstoPCIMNL116FinishBGrade.

2.07

2.08

FABRICATIONTOLERANCES
A. ConformtoPCIMNL116orMNL117
SOURCEQUALITYCONTROLANDTESTS
A. ProvidetestingandanalysisofsiteplacedconcreteandgroutunderprovisionsofSection01400.
B. Maintainshopinspectionandtestingreportsforstressingtendons.
C. TestsamplesinaccordancewithspecifiedASTMandACIstandards.

3.0ERECTION
A. Erectmemberswithoutdamagetostructuralcapacity,shape,orfinish.Replaceorrepairdamagedmembers.
B. Alignandmaintainuniformhorizontalandendjointsaserectionprogresses.
C. Installbearingmaterialorshimsatbearingendsofwallsasindicatedornecessary.
D. Adjustdifferentialelevationbetweenprecastmemberstotolerancebeforefinalattachmentandgrouting.
E. Secureunitsinplace.Grouthorizontaljointsaspershopdrawings.
F. PerformweldinginaccordancewithAWSD1.1.

3.03

ERECTIONTOLERANCES
A. Erectmemberslevelandplumbwithinallowabletolerances.
B. AllworktoconformtoPCIMNL127andPCIMNL135.

3.04

PROTECTIONOFFINISHEDWORK
A. ProtectionofmembersfromdamagefromothertradesbyGeneralContractorthroughoutthejob.

39

SampleSetofGeneralNotes
ThissectionincludesgenericGeneralNotesthatmaybefoundonerectiondrawingsorcontractdocuments.

1.
Precastunitstobedesigned,detailed,manufactured,delivered,andinstalledbyEnConaspercontract.

2.
GeneralContractortoprovidefreeandadequateaccessatjobsitefordelivery,includingtemporaryroadways,cranepad,and
cranepath.

3.
Wallpanelsmustbeliftedwithslingsorliftingeyesunlessnotedotherwise.

4.
Donotlift,store,orsupportwallsotherthanasdetailedbyengineeredcriteria.

5.
Useshimsunderendsofwallsbearingonprecastandcastinplaceconcrete.

6.
Plumbandlevelthewallandgrouthorizontaljoints.

7.
GroutingofhorizontalwalljointsbyEnConaspercontract.

8.
Allopeningsundercontractmustbeshownonthislayoutunlessnotedotherwise.

9.
Anydrillingorcuttingofholes12in.orsmallerinanydirectionisbyothers.

10. Noprestressingstrandand/orreinforcingshallbecutinfieldunlessapprovedbyEnConDesign.

11. AllholesmustbeapprovedbyEnConDesigninwritingpriortodrillingorcutting.

12. Alltradesaretoremainoutofcontrolaccesszoneareasuntilfieldcrewshavecompletederecting,leveling,andgrouting.

13. ModificationsrequiredduetofieldsurveymaybetheresponsibilityoftheGeneralContractor.

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

15. Unless the wall is supported on precast, the General Contractor shall be responsible for providing true and level bearing
surfacesforitssupport.

16. JointsealantsandcaulksareexcludedbyEnConandsuppliedandinstalledbytheGeneralContractor.

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ContactList:
2140SouthIvanhoe,Suite100
Denver,CO80222
303.298.1900

2140SouthIvanhoe,Suite100
Denver,CO80222
303.298.1900

8600WelbyRoad
POBox29039
Denver,CO80229
303.287.4312

1615SE6thAvenue
Camas,WA98607
360.834.3459

101SouthIndustrialLoopRoad
Tooele,UT84074
435.843.4230

5415189thStreetEast
Puyallup,WA98375
253.846.2774

3210AstrozonBoulevard
ColoradoSprings,CO80910
719.390.5041
StressconDenverMetroDivision
5434GrandViewBoulevard
Dacono,CO80514
303.659.6661

80DeHuntDrive
Buchanan,GA30113
770.646.1888

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