CPCI Educational Presentation Thin Brick and Stone Faced Precast Concrete Panels

Introduction The proper selection of colour, form, and texture for a building’s precast concrete exterior is critical in creating a successful aesthetic appearance. By varying and combining aggregates, matrix colour, finishing processes, profiles and depth of exposure, different colours and textures can be achieved along with embedding brick and stone veneers into precast concrete panels Precast concrete is cast in a fluid state that allows architects to create designs that cannot be accomplished with other materials.

Texture – clay product-faced (thin brick) We can also embed thin brick products in our precast concrete panels and we have different methods and formliners to achieve a high performance masonry façade. Masonry of course, is a typical option for school design and a good material for creating scale. Thin brick is real masonry – it is fired at higher temperatures, and has a lower water absorption rate. Thin brick, bonds well with high strength concrete, and exceeds the bond strengths of conventionally laid masonry with mortar. Thin brick is integrally cast in our 5,000 + psi concrete –impervious to moisture penetration, so we don’t require an air cavity or methods to extract moisture. We can eliminate the need for costly on-site storage and scaffolding. And panels are erected in a greatly reduced time.

High performance thin brick is offered in standard brick sizes and offers numerous advantages over traditional materials – no mortar, no air space, reduced weep joints, no lintels, no flashing, no waterproofing, no efflorescence, no freeze/than, no dovetail anchors

Formliners for casting thin brick are offered in numerous coursing and joint options.

And thin brick is made in various colors, textures and finishes.

5,000 psi concrete (vs. 750 psi to 2,500 psi mortar) And when embedded in precast concrete panels, thin brick offers increased durability, low maintenance such as no re-pointing, and no efflorescence. A cast-in thin brick, precast, insulated sandwich wall panel becomes a rain barrier system vs. a rain screen system. Cast-in Thin Brick … an innovation for higher performance walls Actual clay masonry products are cast directly into the concrete panels: 5,000 psi concrete (vs. 750 psi to 2,500 psi mortar) Superior durability Ease of maintenance Design flexibility Low moisture absorption <5% No efflorescence

Cast-in Thin Brick Precast exposed w/ reveals Thin Brick form liner for soldier course Window block-out Thin Brick And within a panel, when we leave the brick out, we can create other architectural features. The sills, lintels, and jambs in these windows are integral precast concrete vs. a composite system of differing materials, providing greater resistance to water intrusion. Additionally, since all dimensions stay consistent from the forming method – windows can be pro-ordered vs. openings having to be site measured. Which is another benefit toward accelerating construction. Cast-in Thin Brick Speed of Installation (for a 28' tall wall) Precast -- 4,032 SF installed in one day w/ no site storage, no site waste vs. Brick & Block Cavity Wall -- only 400 SF installed in one day Cast-in Thin Brick Speed of Installation (for a 28' tall wall) Precast -- 4,032 SF installed in one day w/ no site storage, no site waste vs. Brick & Block Cavity Wall -- only 400 SF installed in one day

Texture – clay product-faced (thin brick) Any project can use several colors and textures of thin brick were embedded in the insulated sandwich wall panels. And where the brick was left out, banding or medallions were formed, And we believe leaving the brick out helps make a strong entry statement.

Texture – clay product-faced (thin brick) In humid climates moisture, mold and mildew can be major problem. Buildings designed with as thin-brick, insulated sandwich wall panels can eliminate moisture problems with a high performance, durable, low maintenance structure.

Texture – clay product-faced (ceramic tile) Stone-veneer-faced panels offer many benefits: Multiplane units incorporating sills, heads, returns, projections, and setbacks can be cast into precast concrete panels. Veneered panels can be used at lower building levels and then transitioned to complimentary architectural precast concrete panels at higher levels. Precast can also embed other clay products like ceramic tile in our precast panels – such as at the very Miami-ish School of Architecture at Florida International University. The Paul Cejas School of Architecture Florida International University, Miami, FL Architect: Bernard Tschumi Architects: and BEA International (JV)

Texture – stone veneer-faced Stone can easily be cast into precast concrete panels The aesthetic effect and durability of natural stone can be combined with the strength and design flexibility of precast concrete can avoid the need for stone masons and costly on-site scaffolding and all can be erected more economically as larger integrated panels. World Exchange Plaza, Ottawa Brisbin Brook Benyon Architects, Ottawa

Architectural panelization is cost effective and precast friendly Brick or Stone-veneer-faced panels offer many benefits: Multiplane units incorporating sills, heads, returns, projections, and setbacks can be cast into precast concrete panels. Veneered panels can be used at lower building levels and then transitioned to complimentary architectural precast concrete panels at higher levels

Best School 2012 PCI Design Awards Precast samples Supplied shellstone sample Casting bed (w/ shells) Dubiski Career nd Technology High School Grand Prairie ISD, TX Architect: Corgan Associates Inc. $45 million, 260,000 SF 59,425 SF - 288 pieces of precast insulated panels of varying sizes Precasters can also create other unique custom finishes. At the Dubiski Career and Technology High School, precast was used on the south and west sides of building using the acoustical properties of precast to buffer highway noise and for thermal mass. The finish process was created to match the architect’s 6”x6” sample piece of shell stone …and the architect was adamant that the finish was to be consistently inconsistent –who typically strive for consistency of finish. This project won Best School in the 2012 PCI Design Awards. Best School 2012 PCI Design Awards

Texture – multiple finishes (insulated sandwich wall panel) Acid-etched finish Sand blast finish Thin brick veneer And finally, panels can be produced with multiple color, form and texture within an individual panel. And we should note – when you change materials in the façade of a building – due to the differing rates of expansion and contraction, you have a greater chance of failure, including moisture problems and required maintenance. When you change the aesthetics in a precast structure, you gain durability, lower maintenance and higher performance. Retarder, exposed aggregate finish Precast plant forming/finish exercise w/ PCI Foundation sponsored Precast Design Studios .

Advantages of Precast Concrete Plant Production Precast Products are manufactured in CPCI-Certified facilities where critical variables including mix design, weather conditions, temperature, and consolidation can be closely monitored and controlled. Control of… Curing Strength Gain Bleeding Shrinking and Cracking Higher densities and control of reinforcement cover results in… High resistance to freeze/thaw and chloride penetration

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