1. CPCI Educational Presentation Thin Brick and Stone Faced
Precast Concrete Panels

2. 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.

3. 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.

4. 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

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

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

7. 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

8. 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

9. 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.

10. 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.

11. 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)

12. 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

13. 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

14. 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 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

15. 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 .

16. 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

17. Thank you For more information on precast concrete products www. cpci
Thank you For more information on precast concrete products and