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OLDCASTLE®

PRECAST WALL PANEL SYSTEM

EQUUS DESIGN GROUPARCHITECTS • PLANNERS

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© Oldcastle Precast

TABLE OF CONTENTS

USE OF THIS MANUAL

This Oldcastle Precast Wall Panel System manual has beendesigned to assist Owners, Developers, Architects, Engineers,Contractors, and others interested in learning the benefits anduses of precast wall panels for a variety of applications. Use ofthe information in this manual will be helpful as reference forthe design of buildings; however, every project must be designedto meet local site conditions and other local requirements.

The drawings and other information herein are illustrative only.Neither Equus Design Group, Inc. nor Oldcastle Precast, Inc.makes any representations as to the suitability of the productapplications for any specific design or structure, and bothdisclaim any responsibility for techniques of application,correctness, interpretations, design methods, modifications ormisapplications of the information contained herein.

Since no specific project or overall engineering responsibility isimplied with the use of this manual and the information containedwithin, neither Equus Design Group, Inc., nor Oldcastle Precast,Inc., will be responsible for the failure of any designer to properlydesign nor any contractor to properly construct any building.

For more information, visit us at www.oldcastlesystems.com

Introduction to Oldcastle Precast

Total Cost of Ownership

Wall Panel Applications

Wall Panel Design Guide

Architectural and Structural Details

Sustainable Design

Case Studies

References & Resources1 2

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© Oldcastle PrecastOP.1

“DELIVERING RELIABILITY”

OLDCASTLE PRECAST WALL PANEL SYSTEM

TECHNOLOGICAL LEADERSHIP

THE NATION’S PRECAST LEADER

ENVIRONMENTAL LEADERSHIP

Oldcastle is a national leader of innovative newtechnologies to support advancement in the designand manufacturing of precast concrete wall panels.Since insulated wall panel technology arrived in theUnited States five decades ago, Oldcastle has beensteadily advancing improvements including a majorleap forward with the introduction of carbon fibergrid reinforcing, a new method of providing non-corrosive, super-insulated, lighter-weight precastwall panels. As a founding member of AltusGroup,Inc., the nation’s first partnership of precastconcrete manufacturers dedicated to carbon fibertechnology, Oldcastle continues to maintain itsleadership role in the industry.

Oldcastle Precast is the largest provider of precastconcrete engineered solutions in North America.Oldcastle continues to improve its dominant marketposition with over 80 locations nationwide and 5,000dedicated employees. Owners, Architects,Engineers, Contractors, and Distributors rely onOldcastle Precast for best-in-class in constructionproducts. Our products service the entireconstruction spectrum, including building systems,electrical, transportation, communications, CATV,drainage, and environmental markets. OldcastlePrecast Building Systems serves the Mid-Atlantic,Northeast and New England Regions and isOldcastle’s leader in Precast Wall Panel Systems.

The Leadership in Energy and Environmental Design(LEED®) Green Building Rating System™ has gainedrapid acceptance since its inception in 2000.Oldcastle’s system of Precast Wall Panels is leadingthe precast industry in ways to make greener, moresustainable precast products available to Ownersand Designers. Oldcastle’s carbon fiber reinforced,highly insulated, thermally broken, weathertight,energy efficient wall panels, built with local materialsand recycled content, provide numerous costbenefits to Owners and help both Owners andDesigners in their mission for LEED certification.

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TCOTotal Cost of Ownership of the Oldcastle Wall PanelSystem includes important, cost-saving, valuedriven benefits including:

Partnering AdvantagesProduct QualityEnergy Cost SavingsSpeed of ConstructionDurabilityReduced MaintenanceReduced Insurance PremiumsFire SafetyLong LifeSecurityStrengthReduced Construction RiskSanitationVersatilityHuman ComfortMoisture ResistanceSustainable Design

VALUE DRIVEN BENEFITS PARTNERING ADVANTAGESTCO - IN THE OWNER’S INTEREST

Total Cost of Ownership is not only the cost ofpurchase, but all costs related to the use andmaintenance of an asset.

Owners, Developers, Designers, and Builderscarefully measure all associated costs over the lifeof a building when selecting building components.The exterior walls of a building are generally amongthe most important building components thatdetermine Total Cost of Ownership.

Oldcastle recommends the creation of partnershipswith Owners from design concept through buildingcompletion. By working closely with the owner’steam early in the design phases, Oldcastle canprovide timely design assistance to ensure that theattributes of Total Cost of Ownership are maximizedto the Owner’s benefit. A clear example of thebenefit of early partnering is the creation of themost design effective sizes and shapes for precastcomponents in order to minimize the costsassociated with casting, transporting and erectingpieces.

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TOTAL COST OF OWNERSHIP

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PRODUCT QUALITY

Oldcastle’s system of design and production forprecast wall panels includes rigorous proceduresleading to the highest quality products at the lowestpossible cost.

Plant vs. Site ConstructionFactory controlled conditions, including weatherenclosure, temperature control, and computerizedfactory batching, provide the type of product qualitycontrol that is not available for on-site construction,except at high cost.

PCI Certified ProductionAll Oldcastle Precast Building Systemsmanufacturing facilities are certified by the mostrigorous standards in the industry, those of thePrecast/Prestressed Concrete Institute, PCI.

Vendor CertificationsAll vendor’s associated with Oldcastle’s products arerequired to follow stringent industry certification andtesting standards.

Independent Plant AuditsAs part of its quality control procedures, all Oldcastleplants receive semi-annual, unannounced, extensivequality audits by an independent engineering firm.

Engineering SupportOldcastle provides full engineering design and shopdrawing support to coordinate with other trades forhigh-quality project integration.

Design ServicesOldcastle’s staff works closely with owners andarchitects throughout the design and buildingconstruction process providing expert designassistance, project management, budget estimatingand erection services.

SPEED OF CONSTRUCTION

Construction time and costs are both reducedsignificantly with the use of Oldcastle’s precast wallpanel system.

Fast-Track SequencingPanels can be cast and stored at the Oldcastle plantwhile the permitting process is underway and whilesite and foundation work is proceeding.

Year-Round ConstructionDespite harsh summer or winter weather at thejob site, Oldcastle’s factory weather-controlledconditions allow for continuous production.Similarly, shipment and erection of panels is rarelyslowed due to weather constraints.

Fast ErectionPanels are erected quickly enabling the contractorto enclose the building to speed interior work andenable fast occupancy for a quicker income stream.It is not unusual to install 220 LF of perimeter wallin a day with heights exceeding 40 feet.

Reduced Construction CostsFactors that reduce construction costs, from theuse of precast wall panels include: reducedtemporary heating and general conditions tofacilitate on-site construction; faster constructionperiod resulting in reduced construction andconstruction financing costs; and, avoidanceof delays due to unanticipated bad weather thatcan plague the schedule and costs of on-siteconstruction.

ENERGY COST SAVINGS

Oldcastle’s fully insulated precast wall panel systemis the nation’s leading energy-efficient buildingenclosure system creating maximum energy costsavings.

Maximum Insulation BenefitOldcastle provides high R-Value insulationthicknesses to meet the most demanding designspecifications.

No Thermal BridgingUsing the CarbonCast® shear grid system, Oldcastlecreates precast panels with insulation to separatethe outer and inner wythes of concrete at the mostdemanding locations such as door and windowopenings and roof and foundation connections.

The Thermal Mass BenefitConcrete has an inherent mass that convenientlyabsorbs and stores heat from both the sun andinterior ambient heat. This helps to avoid largedaily temperature fluctuations thereby reducingHVAC loads and lowering energy consumption. Theresult is lower heating and cooling costs.

Minimum InfiltrationPrecast panels create large, uniform surface areasof the building exterior. Unlike masonry, metal orother building systems, there are very few joints ina precast wall system, thereby minimizing air andvapor infiltration.

Recycled ProductThe recycled material, use of local material in theconcrete mix, and very little on-site waste,contribute to its growing reputation as the greenbuilding product of choice.

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DURABILITY

Precast concrete is built to last. With concrete mixesroutinely in the 5,000 to 6,000 psi range, the wallpanels can withstand abuse, both on the exteriorand interior, unlike any other product.

Reduced Maintenance CostsThe weather and impact-resistant characteristicsof precast concrete result in reduced operating andmaintenance costs, particularly for heavy-dutyfacilities such as manufacturing and warehousestructures.

Reduced Replacement CostsUnlike many of the products in a building thatrequire replacement over time due to break-downsand/or required updates, the precast panels willcontinue to gain strength, resulting in long-termcost savings and sustained building value.

PROPERTY PROTECTION

Precast concrete provides owners a buildingenclosure that protects the Owner’s valuableproperty investments. At the same time, precastconcrete buildings meet the most stringentrequirements of the actuaries who set insurancerates based on a number of fire, security andweather factors.

Fire ResistancePrecast concrete’s inherent, inorganic, high fire-resistance properties help to reduce both the costof fire protection systems and insurance rates.

SecurityBy selecting a virtually impenetrable precast wallpanel system, building owners reduce the risk ofsecurity breaches that can lead to loss of propertyand high insurance premiums.

Weather ResistanceHarsh weather conditions are least likely toadversely affect an Oldcastle enclosed buildingcompared to other exterior facades, a fact thatcreates more favorable rates in the insuranceindustry for buildings built of concrete.

Resistance to the ElementsConcrete wall panels are far more resistant to theelements of nature, such as moisture, mold, rot,termites, rodents, and even fire and hurricanes thanany other building enclosure system.

Moisture ControlOne of the most important benefits of a continuouslyinsulated precast sandwich panel is its inherentability to control moisture. The assembly of an 8”concrete panel (2-1/2” concrete, 3-1/2” eps or xpsinsulation, 2” of concrete) can produce an M(permeance) of < 1.0, qualifying it as a vaporretarder and an air barrier. The continuouslyinsulated wall system also manages surfacemoisture by controlling condensation occurrenceson both the exterior and interior faces.

Furthermore, precast concrete is one of the bestbuilding materials available to inhibit or prevent moldgrowth. Concrete is non-organic and mold requiresmoist organic nutrients to grow. Also, the lowpermeability of precast concrete inhibits thepenetration of mold spores from the exterior.

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WALL PANEL APPLICATIONS

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© Oldcastle PrecastWP.0

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WALL PANELAPPLICATIONSMost medium to large scale projects benefit from theproduct quality, speed of construction, energy cost savings,reduced maintenance, and insurance cost savings offeredby Oldcastle’s precast wall panels.

The benefits of using Oldcastle’s Precast Wall Panel Systemhave an increasing number of owners and developersapplying the system to a wide variety of building types:

WP.2 INDUSTRIALDISTRIBUTION CENTERSWAREHOUSE FACILITIESMANUFACTURINGFOOD PROCESSINGDATA CENTERSINDUSTRIAL PARKS

WP.6 RETAILSUPER CENTERSSUPERMARKETSDEALERSHIPSSHOPPING CENTERSRETAIL OUTLETS

WP.8 SPECIAL USESENTERTAINMENTCULTURAL BUILDINGSPRODUCTION STUDIOSATHLETIC FACILITIESTRANSPORTATION

WP.10 INSTITUTIONALEDUCATIONALCORRECTIONAL

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SUPERMARKETS

OLDCASTLE PRECAST WALL PANEL APPLICATIONS

EDUCATIONAL

THEATERS

RETAIL SUPERCENTERS DISTRIBUTION CENTERS MANUFACTURING

DATA CENTERS INSTITUTIONAL

ENTERTAINMENT

INDUSTRIAL PARKS

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Oldcastle’s Wall Panel System has increasingly becomethe product of choice for industrial building owners,developers, contractors and designers.

American manufacturers and distributers trend towardlarger and taller facilities, flexibility forexpansion, high energy efficiency, rapid delivery,durability, and corporate aesthetics make Oldcastlewall panels the most desirable building product forindustrial related applications.

The wide array of building uses and types particularlywell-suited for Oldcastle’s complete system of wall paneldesign and production include:

DISTRIBUTION CENTERS

WAREHOUSE FACILITIES

MANUFACTURING

FOOD PROCESSING

DATA CENTERS

INDUSTRIAL/INDUSTRIAL PARKS

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TRENDS ININDUSTRIALBUILDINGS

The National Association of Industrial and OfficeProperties (NAIOP) reports that major trends inAmerican manufacturing and distribution includeconsolidation and development of majormanufacturing and distribution operations (fewerlocations and larger facilities); the need forflexibility (to accommodate growth and change);and, an increased awareness of energy andenvironmental issues.

The trend toward larger “megabox” projects,according to NAIOP is both in the “build-to-suit”and speculative development markets. Among thedesign features include trends for higher ceilings,larger building footprints, and more cross-docking operations to increase speed-to-market.

Oldcastle’s Precast Wall Panel System is designedto meet the trends of the industry through a varietyof innovative measures.

Larger and Taller Facilities

Taller interior ceiling heights require taller exteriorwall heights. Oldcastle’s technological solutions fora system of lighter-weight, yet stronger andmore energy efficient, precast panels allows forthe production, shipping and erection of individualpanels up to fifty feet tall.

As the nation’s leading precast manufacturer,Oldcastle has the plant and personnel capacity tomeet the needs of owners and builders requiringhigh volume production for large projects withdemanding construction schedules.

Panels are erected full height, independent of otherwork on site. The result is unparalleled speed ofconstruction, and completion dates impossible withother wall systems.

Precast wall systems also provide maximum spaceutilization when using load-bearing panels withoutperimeter support columns. And, precast panelsallow wider openings without incurring anypremium costs or conventional framing.

Flexibility for Future Expansion

As businesses continue to develop, the need toremain flexible enough to accommodate addedgrowth is a key element of most business plans.

Adaptable System of ComponentsTo meet the need for flexible building expansion,Oldcastle has created a system of precast wall panelproducts that can be modified for building expansionand reorganization. The system of non-load bearingpanels is designed for relatively easy disconnectionand movement to open sides of a building forexpansion. And, Oldcastle’s creative ability to designwhole buildings with the fewest number of panelsand parts, makes adaptation even easier.

Aesthetic Considerations of ExpansionBecause Oldcastle’s panels are produced underquality controlled factory conditions, new additionalpanels can be manufactured to closely match and/or complement the textures and colors of theoriginal panels.

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Energy and Environmental Issues

Oldcastle’s thermally broken, highly insulated wallpanels are the most energy efficient precastproducts available on the market.

Concrete – The Earth’s Natural ResourceOldcastle’s Precast Wall Panel System consists ofan environmentally sound material, produced fromsustainable resources with energy resourcefultechniques:• Concrete is produced from natural materials.• No toxic substances are produced in its

production or use.• The production energy consumption of concrete

is quite small.• The dense, impervious nature of concrete saves

energy year-round by reducing temperatureswings.

• And, after its original purpose has been served,concrete can be crushed and recycled back intothe environment.

Furthermore, the recycled material in the concretemix and very little on-site waste contribute to itsgrowing reputation as the green building productof choice.

Thermal BreaksAmong the largest contributors to building energyloss are the thermal bridges where the insulationin wall panels is not continuous throughout thepanel, particularly at edges, openings and wytheconnectors.

However, Oldcastle’s Precast Wall Panel System cancarry the insulation completely through to the edgesof the panels at window and door openings, as wellas at roof and foundation intersections, creating atotally continuous and highly energy-efficientenvelope.

Furthermore, with the use of low-conductivitycarbon fiber shear grid to connect the outer andinner layers of concrete sandwiching the insulation,there is added assurance of maintaining the mostenergy efficient panel design available.

High R-ValuesWithin Oldcastle’s system of carbon fiber reinforcedsandwich panels are thick layers of rigid insulationwith the highest R-values attainable in precast walldesign. Oldcastle offers R-values up to R-30 andeven higher, to meet the needs of the most energyconscious owners and designers.

Cross Docking

An increasingly prevalent system of rapid movementof materials from distribution facilities to their nextdestination is the use of a greater number ofshipping docks and staging areas. This practice,referred to as cross docking, helps to streamlinethe flow of product from receiving to shipping witha minimum of handling and storage in between.

Oldcastle’s wall panel system is adaptable to avariety of dock types, heights and widths to suitthe owner’s needs for the most efficient and heavy-duty dock designs. The precast concrete panelsare designed to withstand the abuse and high-intensity traffic associated with cross-dockoperations; and, Oldcastle’s system accepts thedock levelers, seals, shelters, doors, and accessoriesof the nation’s leading manufacturers.

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Durable and Maintainable

Both on the inside and the outside of the building,Oldcastle’s precast concrete wall panels provide ahardened finish that reduces the effect of impactif hit by vehicles or heavy equipment. At the sametime, concrete wall panels are far more resistantto the elements of nature, such as moisture,mold, rot, termites, rodents, and even fire andhurricanes, than any other building enclosuresystem. Oldcastle’s precast wall panels are durableand easily maintainable ensuring long-lastingattractiveness and desirability to future tenants andowners.

In the food industry, precast wall systems offerprocessing plants economical, effective ways tomeet government standards, especially thosegoverning a clean, germ-free environment.

Aesthetics and Corporate Identity

Whether designing in a style to complement existingbuildings, or in a unique style for stand-alonefacilities, or as sets of buildings in an industrial park,Oldcastle has the precast kit of parts and palette offinishes, textures and colors to suit the needs ofowners and architects.

Corporate IdentityOldcastle Precast wall panels are extremely versatilein providing unique and custom ways to help yourbuilding stand out and be recognized, if desired.Wall panels can be created in a wide variety ofshapes and configurations; and with the use ofspecial formliners, virtually any design, corporatelogo or text imaginable can be incorporated intothe wall panels. The precast wall panels can alsobe used to support canopies, full glazing, and otherconfigurations at the building entry or otherlocations.

FinishesOldcastle offers several types of panels in a varietyof finishes. From our formliner finishes to revealsand custom mix designs, we can give any wall panelfacility a distinctive exterior reflecting the desire ofthe owner. For less public facades, we can alsoprovide economic finishes to give all of the benefitsof precast, but at less cost.

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In the modern era of “Big-Box” stores, “Supercenters,”and Wholesale Warehouse Stores, with large footprintsand tall spaces, Oldcastle’s precast wall panel productsare particularly ideal.

By providing the opportunity to eliminate perimetercolumns and beams, Oldcastle wall panels allow foreasy rack and storage along exterior walls, increasinginterior space and layout flexibility and increased safetyfor fork lift operation, as well as other benefits.

Oldcastle’s Precast Wall Panel System provides Owner’swith advantages for retail projects such as:

SUPER CENTERS

WHOLESALEWAREHOUSE STORES

SUPERMARKETS

DEALERSHIPS

SHOPPING CENTERS

RETAIL ANDSUPER CENTERS

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WP.7

ADVANTAGES FORRETAIL BUILDINGS

Among the advantages of precast wall panels forretail buildings include:

Rapid Production and Erection

Eliminate Perimeter Columns and Beams

Energy-efficient Insulated Design

Interior Durability

Flexible, Wide Open Interior Layouts

Added Security

Reduced Maintenance Costs

Appealing Exterior Aesthetics

Expansion Capability

Systemized Loading Dock Design

Clean Germ-Resistant Environments

Eliminate Interior Girt Framing

Reduced Exterior Noise Transmission

Increased Safety for Fork Lift Operation

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WP.8

SPECIAL USEFACILITIES

With the ability to easily provide large flexible openspaces with high ceilings and excellent acousticalseparation, the Oldcastle wall panel system is ideal formany unique and special uses.

Among the special use facilities that Oldcastle’s PrecastWall Panel System is particularly suited includes:

ENTERTAINMENT/THEATERS

CULTURAL BUILDINGS

PRODUCTION STUDIOS

ATHLETIC FACILITIES

TRANSPORTATION

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CONSIDERATIONSFOR SPECIAL USEFACILITIES

Movie theaters, skating rinks, athletic clubs, andother recreation facilities are excellent opportunitiesto use the advantages of Oldcastle’s Precast WallPanel System and its related components.

The high performance, low maintenance,insulation, and durability of precast concrete makeit ideal for both public and private facilities.

The design flexibility and versatility of precastconcrete can give your amusement/recreationproject both a functional interior space as well as apleasing exterior, whether to blend into an existingneighborhood or stand out as a bold statement.

The ease of maintenance and durability ofprecast concrete also make it an ideal material forreducing long term costs. Heavy use and high trafficcan create chronic maintenance issues for othersystems, but precast concrete’s durability is theticket for a cost-effective structure, not only atconstruction, but also long into the project’s life.

The long-span and high-strength opportunities withprecast also help in the design of wide openspaces with unobstructed views; and the soundand vibration attenuation characteristics add tothe enjoyment of the facility’s users.

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INSTITUTIONAL

Institutional facilities, typically publicly funded, arehighly visible buildings that, due to their inherent highuse and high traffic, are prone to maintenance anddurability issues.

With many municipalities struggling with budgetshortfalls, overcrowding and out-of-date buildings, theOldcastle Precast Wall Panel System, with itscompetitive cost, speed of erection, inherent durability,ease of maintenance and sound attenuation, is idealfor institutional uses including:

EDUCATIONALCLASSROOMSLABORATORIESGYMNASIUMSMULTI-USECAFETERIASASSEMBLY HALLS

CORRECTIONALPROGRAMSWAREHOUSERECREATIONHOUSING

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CONSIDERATIONSFOR INSTITUTIONALFACILITIES

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EDUCATIONAL FACILITIES

The sound and vibration attenuation characteristicsof precast concrete make wall panels ideal foreducational uses by reducing outside noise anddistractions and helping to provide a quality learningenvironment for both students and faculty. Thelow maintenance and durability of concrete alsohelps reduce long term costs and maintenanceissues. With the ability to provide long spans andhigh ceilings, the Oldcastle wall panel system isadvantageous for educational, classrooms,laboratories, gymnasiums and multi-use spaces.

CORRECTIONAL FACILITIES

Safety and security for correctional officers, civilianemployees and inmates is paramount insidecorrectional facilities. The Oldcastle wall panelsystem, with the ability to create large, wide-openspaces with unobstructed views for visibility, securityand safety is ideal for program spaces, warehousing,recreation and housing areas within correctionalfacitilities. The strength, durability and ease ofmaintenance of precast concrete also assists inreducing facility maintenance and budget costs.

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WALL PANEL DESIGN GUIDE

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© Oldcastle PrecastDG.0

WALL PANELDESIGN GUIDEThe Oldcastle Precast Wall Panel System is the nation’smost advanced complete wall panel system. With itsflagship product, the CarbonCast® High PerformanceInsulated Wall Panel and its industry breakthrough designfeatures, Oldcastle has built upon its reputation as thenation’s preeminent precast leader.

This section of the manual provides information andguidelines for Owners, Designers and Contractors aboutthe Oldcastle Precast Wall Panel System, including:

DG.1 WALL PANEL TYPES

DG.4 PANEL SIZES AND TOLERANCES

DG.8 MANUFACTURING,TRANSPORTATION AND ERECTION

DG.12 LOADING DOCKS

DG.14 FACADE TREATMENT OPTIONS

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Oldcastle produces precast concrete wall panel typesto suit the specific needs of each owner and project.Wall panels come in a variety of forms and functions,including load and non-load bearing, insulated and non-insulated, and composite and non-composite panels.

The two most common types of wall panels made byOldcastle are the CarbonCast® Panel and the SolidPanel. Other wall panel types, such as flat slabsandwich panels, are available for special applications.

WALL PANEL TYPES

P R E C A S T P R O D U C T SP R E C A S T P R O D U C T S

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1

DG.2

2

4

The CarbonCast® High Performance Insulated WallPanel is the first major innovation in precastconcrete in more than half a century, since thedevelopment of prestressed precast concrete.

CarbonCast® adds even greater long-term durability,lighter weight, finer finishes, improved insulatingproperties and greater sustainability to the alreadylong list of precast benefits.

CarbonCast® High Performance Insulated WallPanels use the patented C-GRID™ epoxy-coatedcarbon fiber trusses for shear transfer to achieve afully structurally composite panel. The C-GRID isover four times stronger and less thermallyconductive than conventional wythe connectors.

The results are:

Energy Efficient and Lighter WeightThe exceptional bonding and strength of C-GRIDtrusses allow the use of less concrete and moreinsulating foam to reduce energy use andlighten panels.

Superior at Load-BearingCarbonCast® vertical panels are available forboth loadbearing and non-load bearingapplications, and can be manufactured inthicknesess 8" to 12", with widths up to 13’-6”and heights of 50’ or more.

GreenerLess energy is used in the fabrication anddelivery of the CarbonCast® panels, and theenhanced thermal efficiency of the highlyinsulated panels results in reduced energyexpenditures.

CarbonCast® Panel

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SOLID PANEL

Solid panels are uninsulated flat slab concrete panelsof uniform thickness, typically 6 to 8-inches, whichare cast on flat forming beds within controlledfactory conditions. Non-load bearing conditionstypically require no more than a 6-inch thickness,whereas load-bearing conditions usually require 8-inches. Solid panels can be made in a wide varietyof shapes and configurations.

Solid panels are typically used for specialapplications such as:

• Interior bearing walls and fire walls withoutthe need for insulation.

• Institutional buildings requiring unique, deepthickness for security reasons, e.g.correctional and other high-securityapplications.

• Residential and commercial applicationswhere the owner and designer seek toinsulate walls separately and apply specialtyinterior finishes.

FLAT SLAB SANDWICH PANEL

Available in both composite and non-compositepanels, the flat slab insulated sandwich panel hastwo layers of concrete with rigid insulationsandwiched in between.

Cast in a form on a flat bed, these panels can bemade in a wide variety of shapes and configurations.

WALL PANEL DEFINITIONS

Sandwich Panels are concrete wall panels thathave two layers of concrete separated by a layer ofrigid insulation. They can be broken down evenfurther into Composite and Non-composite sandwichwall panels.

Composite panels are fabricated so that the twolayers of concrete, with rigid insulation between,act together as a single unit to resist applied loadsby providing a shear transfer between the concretewythes.

Non-Composite panels are fabricated with twoconcrete wythes acting independent of each other,with rigid insulation between, typically with a non-structural exterior wythe and a thicker structuralinterior wythe.

Wythe connectors are used to tie two concretewythes together. They penetrate the rigid insulationand are embedded in each concrete wythe. Thereis a wide range of connector sizes, shapes andmaterials based on the structural requirements ofthe wall panel. However, the CarbonCast® C-Gridis the most economical thermally and structurallyefficient connector currently available.

Insulation used in concrete wall panels is of thecellular (rigid) type because it provides materialproperties that are most compatible with concrete.Cellular insulation comes in two main types,thermoplastic and thermosetting.

SOLID PANELS are typicallyused as interior partition wallsand can be either load or non-load bearing. These panelscan weigh from 75 to 100 psf.

NON-COMPOSITE/NON-LOAD BEARING PANELSare typically used forcomponents and cladding.Designed to resist only theirself weight and wind loads,these non-structural panelsweigh approximately 75 psf.

NON-COMPOSITE/LOADBEARING PANELS have athicker interior wythe whichis used to support thestructural frame. The exteriorface of the panel is anarchitectural and non-structural concrete wythe.These panels weigh from 110to 120 psf.

COMPOSITE/LOAD ANDNON-LOAD BEARINGPANELS are structural panelsthat have both concretewythes tied together to act asone with low-thermallyconductive carbon trusses.These structural panels arelighter and thinner than othersand weigh approximately 75psf.

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Oldcastle Precast Wall Panels are produced in a varietyof sizes to meet the needs of most clients and buildingtypes. Oldcastle’s team of specialists provide valuableexpertise for selecting cost-effective methods ofcreating panel sizes that take into account manyvariables - plant capacity, shipping constraints, craneconsiderations, and efficient building design. Owners,designers and contractors also need to be aware oftolerance standards for the different phases of wallpanel construction, from fabrication to erection tointerfacing with other building materials.

WALL PANEL SIZESAND TOLERANCES

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Economy Rules Of Thumb

DG.5

WALL PANEL SIZES

Oldcastle precast wall panel sizes are a function ofcrane and truck limitations as well as manufacturingconsiderations. With effective planning during theearly design phases of a building, economicadvantages can be obtained.

Crane and Truck Considerations

With an average panel weight of 75 lb/sf, themaximum precast wall panel size is largelydetermined by plant and site crane capacities aswell as the capacity of the transporting truck andweight limit restrictions of various states’ roadways.

Oldcastle typically transports wall panels withlowboy or drop deck truck trailers. Depending onlocal transportation regulations, most panels 12 feetwide by 40 feet long can be shipped without specialpermits. However, panels up to 13’-6” wide by 50feet long, and even longer if necessary, can betransported on tilt frame trailers, usually requiringspecial permits and/or escorts.

Manufacturing Considerations

The cost of precast concrete wall panels isdetermined primarily by piece size and piecerepetition. The labor cost of setting up forms forthe production of concrete panels can be expensiveif used for a single pour; however, with re-use ofthe same form for repetitive panels, the panelsbecome increasingly cost-effective. This isparticularly true for panels with openings, reveals,and other special surface features. The morerepetition, the less the cost of the panel.

Early Planning With Oldcastle

Close collaboration of the owner and designer withOldcastle’s talented group of architects andengineers to determine the most effective mannerto achieve overall design goals can lead to significantcost savings.

Repetition of panel sizes, openings and detailssaves costly form setups and changes.

Maximizing panel sizes creates fewer pieces andresults in:

• Fewer setups• Fewer castings• Fewer crane picks

(plant and site)

• Fewer transports• Fewer connections• Faster erection

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Tolerance refers to the permissible limit ofdimensional variation in building construction. Thetolerances of precast concrete wall panels in buildingconstruction refer to the set of dimension variationsthat are reasonable for fabrication, erection, joints,and interface with other building materials.

It is important for the owner, designer, contractor,and precast manufacturer to have a clearunderstanding of the expectations of tolerances.

The Precast/Prestressed Concrete Institute (PCI)establishes tolerance standards that are widelyaccepted in the building industry. The groups oftolerances established by PCI for precast design are:product tolerances; erection tolerances; andinterfacing tolerances.

Product TolerancesProduct tolerances refer to the dimensions ofindividual precast components, including length,width, thickness, shape, and size and location ofopenings. Refer to PCI Manual 116 for ProductTolerances.

Erection TolerancesErection tolerances refer to the placement of theindividual precast products in relationship to theadjacent construction. Unlike product tolerancesthat are set by the ability to produce in a factory-controlled environment, erection tolerances involvethe general contractor, other subcontractors and theprecast erector. Refer to PCI Manual 127 for ErectionTolerances.

Interfacing TolerancesInterfacing tolerances are those set for the joiningof precast components to adjacent precastcomponents and/or other building materials.Examples include window and door openings andjoints.

Finish TolerancesDuring the design phase it is recommended thatthe owner request a 12” square sample of theselected color, texture and finish for final approval.Prior to initial panel fabrication it is recommendedthat a 48”x48” or 96”x96” panel mock-up be createdto establish a minimum acceptable standard for thepanel color, texture and finish.

TOLERANCES

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PANEL EDGE DESIGN

Acceptable production and erection tolerances allowfor some planar differences of panels resulting inpotential planar misalignments. Though direct buttjoints are available and can be provided, it isrecommended that chamfers be used at the edgesof panels. Chamfers help alleviate possible unevenshadow lines of joints, help reduce damage thatmay be caused during storage, transportation anderection, as well as setting the sealant away fromsun and weather exposure.

JOINT DESIGN

The most important performance mission of precastconcrete wall panels is to keep rain and otherweather elements from penetrating the building. Akey advantage of precast concrete over otherexterior wall systems is its relative impermeability– water does not penetrate precast concrete.

Butt Corner Miter CornerButt JointChamfer Joint

Nevertheless, the joints between panels are subjectto weather penetration and it is essential that inthe production and erection of precast panels thatjoint widths meet the exacting requirements forsatisfactory application of sealant materials.

Typical Joint DesignTypical panel joints are 5/8” - 3/4” wide on theexterior and 1/2” on the interior. The typical jointbetween precast panels has a single line of sealantfor weatherproofing and a closed-cell insulatingbacker rod to set the depth and shape of the sealant.Exterior sealant selection should be based on theability to maintain elastic properties, weatherperformance and resistance to harmful UV rays.

Sealant DepthEqual in importance to the width of the sealant jointis the depth. For joints designed for ¾ to 1 inchwide, the depth should be equal to one half thewidth. In plan view the shape of the sealant shouldconcave, similar to an hourglass. The backer rod

provides the interior concave shape; the sealantapplicator provides the tooled concave shape at theexterior. It is essential to avoid depths too shallowor too deep to avoid premature debonding of thesealant to the concrete surfaces.

Expansion JointsWhere considerable movement is expected betweenadjacent wall materials, an expansion joint widerthan a typical joint is designed for sealing withspecialty seals specified by the architect or engineer-of-record.

Corner JointsCorner joints are typically butt joints or quirk miters.Butt joints are more easily fabricated and erected,and special care needs to be taken to ensure theinsulation returns back to the adjacent panel tomaintain the continuous insulation. Quirk mitersrequire more attention during fabrication anderection, but the final position ensures continuousinsulation.

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Oldcastle’s precast wall panels are manufactured yearround inside PCI certified facilities under strict standardsand production procedures. Extreme care is takenduring all phases of the panels movement, fromproduction and manufacturing through transporting anderection, to final building completion, to ensure thehighest quality panel is delivered.

MANUFACTURING,TRANSPORTATIONAND ERECTION

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DG.9

MANUFACTURING Mixtures and Admixtures

Self Consolidating Concrete (SCC) is a velocitymodifier that allows concrete to flow easier andresults in less pitting on the finished surfaces. Thisresults in a smoother, more uniform panel finishwithout segregation of aggregates.

Super Plasticizers, also known as water reducers,are primarily added to concrete to improve theworkability of a concrete mix during the initial pour.

Air Entrained concrete contains microscopic airpockets that allow water to expand and contractthrough freeze-thaw cycles, reducing cracking andspalling and increasing the durability of the concrete.

Photocatalytic Cement has self-cleaning andpollution-reducing properties produced by the useof a photocatalyst, a material that uses solar energyto accelerate chemical reactions. As photocatalyticcement responds to the UV rays in sunlight,oxidation accelerates in the concrete, speeding upthe rate the concrete will decompose pollutants thatcome into contact with its surface.

Forming Beds

Precast concrete panels are typically formed on flatsteel beds with steel rails placed to form the panelsides. Bulkheads, or blockouts, are used to formany openings in the panel. The exterior face of thepanel is typically the bed side, as it produces a verysmooth consistant finish.

Factory Controlled Conditions

All Oldcastle precast wall panels are made withminimum 5,000 psi concrete and can be producedyear round, in all weather conditions, because theyare made inside a plant, in a controlled environment.All Oldcastle plants are PCI certified and are subjectto two, unannounced, quality inspections each yearby an independent engineering firm.

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Shipping SizesPanel sizes up to 13’-6” feet wide and 50 feet longare routinely handled by Oldcastle’s fleet of speciallydesigned truck beds. Laws for shipping sizes andweights vary by each state in which the panels arebeing transported. Early planning with Oldcastle’steam of specialists will lead to a clear understandingof shipping constraints and transportationeconomies.

Erection of CarbonCast® precast panels can beperformed by Oldcastle’s in house field crew, anerection subcontractor, or the general contractor,depending on the most cost effective and logisticallydesirable approach as determined in consultationwith the owner. Early planning by the erectionspecialists is critical for safe, cost effective andefficient scheduling.

Crane Size and Site AccessSpeed and economy of erection are directly relatedto crane size and type; and, crane size and typeare determined by panel sizes; the reach needed;types of connections required; and the potentialfor unencumbered access to the site.

The logistics for erection vary by each site; however,Oldcastle’s wall panels have been erected both inhigh density urban areas with limited access and in

DG.10

areas where access is virtually unencumbered.Proper access and ground stability for trucks andcranes are crucial for a fast and smooth installation.

On-Site StagingTo limit the time needed for expensive craneequipment at the site, it is necessary to plancarefully for its continuous use. Ideally, wall panelsare lifted from the trucks in an orderly manner withlittle down time of the crane. Erection specialists,working with owners and contractors, need to findaccessible staging areas for trucks so thatscheduling of delivery is as efficient and costeffective as possible.

Temporary BracingDepending on site conditions and sequencing ofconstruction, Oldcastle provides a variety of optimalsolutions for the temporary bracing of wall panels.

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TRANSPORTATION ERECTION

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THE MANUFACTURING, TRANSPORTATION & ERECTION OF A PANEL

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1

LOADING DOCKS

The most important area of a distribution center is theloading dock area. This is where productivity isdependent upon efficient layout and design of the areawhere goods are received and shipped.

Increasingly, managers are adopting the practice ofcross docking to expedite the flow of product fromshipping to receiving with a minimum of handling andstorage in between.

Oldcastle’s wall panel system is adaptable to a varietyof dock types, heights and widths to suit the owner’sneeds for the most efficient and heavy-duty dockdesigns. The precast concrete panels are designed towithstand the abuse and high-intensity traffic associatedwith cross-dock operations; and, Oldcastle’s systemaccepts the dock levelers, dock seals, shelters, doors,and accessories of the nation’s leading manufacturers.

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1

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Straight DocksStraight docks are the most economical to buildand they optimize interior space.

Saw Tooth DocksSaw tooth docks are used on restricted site areaswhere trucks are difficult to maneuver in and out ofthe dock area.

Interior DocksInterior docks provide protection from weather, butare the least common type due to their considerablecost to build and operate.

Dock DoorsDock door sizes are dependent on a host of owner-driven factors, not the least of which is the size ofthe vehicles to be serviced. Increasingly, laws andtechnology are allowing trucks to be taller, widerand lower. This requires that loading docks be

capable of being built to a variety of standards andto be capable of accepting specific dock equipmentfor flexible applications. Oldcastle’s Precast WallPanel System provides a virtually unlimited arrayof sizes and styles to meet the owner’s needs.

Energy Efficient Dock DesignThe greatest area of energy loss in a building isoften the area of the loading dock. Oldcastle’ssystem of wall panel design for loading dock areasincludes fully insulated panels with thermal breaksto prevent heat loss or gain due to the effects ofthermal bridging.

At the same time, the Oldcastle system is adaptableto a variety of dock seals and canopies to controltemperature loss while, at the same time, improvingemployee comfort, reducing insect infiltration, andprotecting products.

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FACADE TREATMENTOPTIONS & FINISHES

DG.14

Oldcastle offers a range of colors, textures and otherfaçade treatment options for exterior buildingcomponents. The choice of appropriate aggregates andtextures, combined with well-conceived production anderection details, can achieve a wide variety of designobjectives.

The variety of facade treatment options offered byOldcastle creates an enormous range of designopportunites for owners and architects.

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Precast concrete is a moldable material whichcombines architectural effects with structuralcapacity. A variety of colors, textures and shapesare available for selection.

Various textures such as simulated stone or ribbedformliners can be added to increase visual interestof a panel. Deep reveals and medallions, as wellas large cornices and other features can beintegrated into concrete forms. For owners seekinga traditional masonry appearance, thin brick veneercan be cast directly onto the face of concrete panels.

Colors and Textures

Design flexibility is possible in both color and textureof precast concrete by varying aggregate and matrixcolor, size of aggregates, finishing processes, anddepth of exposure. Combining color with textureaccentuates the natural beauty of aggregates.

Color and, consequently, color tone are affected bylight, shadow, density, time and other surroundingor nearby colors. Color selection should be madeunder lighting conditions similar to those underwhich the precast concrete will be used, such asthe strong light and shadows of natural daylight.Surface texture influences color. The building’sappearance is a function of the architect’s use oflight, shadow, texture and color.

Cement (plus coloring agent) exerts the primarycolor influence on a smooth finish because it coatsthe exposed concrete surface. As the concretesurface is progressively removed and aggregatesare exposed, the panel color increasingly exhibitsthe fine and then the coarse aggregate colors.

Nevertheless, the color of the cement always hasan effect on the general tone of the panel. Cementmay be gray, white, buff or a mixture. All cementshave inherent color and shading differencesdepending on their source; and local sources areoften preferable.

Pigments and pigmented admixtures often areadded to the matrix to obtain colors that cannot beobtained through combinations of cement and fineaggregate alone. White portland cement, forexample, will produce cleaner, brighter colors.

Fine aggregates have a major effect on the colorof white and light buff colored concrete, and canadd color tones when the surface is given a shallowprofile to increase their exposure.

Coarse aggregate colors become dominant as thesurface of the concrete is removed to obtain amedium or deep aggregate exposure profile. Somefinishing processes change the appearance ofaggregates. Sandblasting, for example, will give theaggregate a matte finish.

FACADE TREATMENTOPTIONS

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Architectural Coatings

The U.S. paint and coatings industry offers a diversecollection of product coatings specificallymanufactured for exterior concrete application.Depending upon the visual effects and performancerequirements of owners and architects, Oldcastlecan make specific recommendations for high-performance coatings to suit most conditions.

Coatings that work successfully on concrete includeacrylics, epoxies, and polyurethanes. Generally,alkyd or oil-based coatings should not be specifiedas they may chemically react with the alkalineconcrete and moisture.

For succesful results, coatings must be applied atthe proper thickness, and under proper weatherand temperature conditions, as specified by thecoating manufacturer in product data.

Reveals

A reveal is a groove in a panel face used to create adesired architectural effect. Used effectively, revealsoffer a simple and cost-effective way to break upan expanse of precast concrete. The exteriorarticulation helps designers to modulate the scaleof the building.

Reveals can be placed vertically, horizontally,diagonally, and in a variety of sizes and shapes.Reveals typically measure 1/2” deep with a 45-60degree bevel or “draft” for ease of stripping fromthe concrete form. Generally, the preferredminimum draft for ease of stripping from a mold isone inch in eight inches (1:8), although in specialcases the draft may be reduced to 1:12.

Designers often use reveals in combination withpanel joints to express floor, ceiling or roof lines;emphasize changes in texture; and, highlightplanning modules or structural bays.

Ornamental Decoration

For owners and architects seeking to createornamental decoration or three-dimensional reliefon concrete panels, Oldcastle offers solutions.

Similar to the techniques used for creating reveals,wide recesses can be created in the concrete usingblock-outs within the formwork to provide three-dimensional relief. Blockouts generally have thesame depth and draft considerations of reveals,however they can be large or small depending uponthe desired design effect.

Additionally, clay products such as thin brick, terra-cotta or tile can be cast into the concrete to createornamental decoration. The design possibilities arelimitless. To develop the best adhesion to theconcrete, the backside of the clay products shouldhave grooved or dovetail-like slots.

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SAMPLE CONCRETE FINISHES

Oldcastle Precast offers a wide range ofprecast concrete colors and textures. Thearchitect should contact the local Oldcastlerepresentative in the early design stages andthroughout the development of the design forinformation on how to best obtain the visualeffect desired.

Note:These samples serve only as a visual guidefor initial selection of color and texture. It isimportant to note that the colors and texturesseen will vary depending on local conditions.Since it is impossible to reproduce exactly onpaper the true colors of precast mix designs,some variations from these samples must beexpected.

Additionally, due to different material sourcesor different techniques in various plants, thearchitect should not expect to select aphotographic sample and obtain exactmatching by all precast concrete producers.Samples should be required to ensure thatthe desired colors and textures can besatisfactorily matched.

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01 03 04

Photos courtesy of PCI

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Oldcastle offers owners and architects theoption to integrally cast brick in concrete. Fromthe nation’s premier manufacturers of thinbrick, there is a wide array of brick optionsavailable. Advantages of brick-embeddedconcrete include no flashing, lintels or weepcavities; no efflorescence; and reducedconstruction time.

The images shown here represent a smallsampling of the available color and textureblends. Brick corners and edge caps are alsoavailable. The Oldcastle representative willmake available more accurate color literatureand samples when requested.

FORMLINERSFluted Low Profile Stone

Oldcastle offers owners and architects theoption to cast concrete in forms with specialtyformliners to create almost any desired visualeffect. Oldcastle works directly with thenation’s premier manufacturers of formlinersrepresented in the patterns shown on thesepages. In addition to a vast array of patternsand textures offered as standard, there is alsothe option to create custom formliner finishesin almost any style imaginable.

The images shown here represent a smallsampling of the textures and patternsavailable. The samples shown are only a visualguide for initial concept, not for actualselection. The Oldcastle representative willmake available more accurate literature andsamples when requested.

Fractured Rib

THIN BRICK

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ARCHITECTURAL &STRUCTURAL DETAILS

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AS.1ARCHITECTURAL DETAILS

USE OF THESE DETAILS

The drawings and other information contained herein are illus-trative only and neither Equus Design Group, Inc. nor OldcastlePrecast, Inc. makes any representation as to their fitness forany specific design or structure, and disclaim any responsibilityfor techniques of application, correctness, interpretations, de-sign methods, modifications or misapplications of these draw-ings and references.

Since no specific project nor overall engineering responsibility isimplied with the use of this manual and the information con-tained within, neither Equus Design Group, Inc. nor OldcastlePrecast, Inc. will be responsible for the failure of any designerto properly design nor any contractor to properly construct anybuilding.

TYPICAL FOUNDATION DETAIL3 TYPICAL FOUNDATION DETAIL4

TYPICAL LOAD BEARING PANEL DETAIL1 TYPICAL NON-LOAD BEARING PANEL DETAIL2

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TYPICAL BUTT CORNER DETAIL1 TYPICAL MITER CORNER DETAIL2

TYPICAL CARBONCAST PANEL SECTION4

TYPICAL BUTT PANEL-TO-PANEL DETAIL3


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SOLID PANEL OPENING DETAIL4 INSULATED PANEL OPENING6

HEAD

JAMB

HEAD

JAMB

HEAD

JAMB

INSULATED PANEL OPENING WITH BLOCKING5

SOLID PANEL OPENING DETAIL1 INSULATED PANEL OPENING3INSULATED PANEL OPENING WITH BLOCKING2


NOTE

There are numerous ways to detail wall panel openings. Thedetails shown on this sheet are some examples. Dependingon many variables - level of use (heavy or light), insulationrequirements, and size of opening, each detail can be usedfor roll-up doors, man doors, windows and louvers.

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AS.4

USE OF THESE DETAILS

These details represent a sampling of typical Oldcastle BuildingSystem details for various building conditions. Please consultan Oldcastle representative for specific details for each project.

The drawings and other information contained herein are illus-trative only and neither Equus Design Group, Inc. nor OldcastlePrecast, Inc. makes any representation as to their fitness forany specific design or structure, and disclaim any responsibilityfor techniques of application, correctness, interpretations, de-sign methods, modifications or misapplications of these draw-ings and references.

Since no specific project nor overall engineering responsibility isimplied with the use of this manual and the information con-tained within, neither Equus Design Group, Inc. nor OldcastlePrecast, Inc. will be responsible for the failure of any designerto properly design nor any contractor to properly construct anybuilding.

TYPICAL NON-LOAD BEARING JOIST CONNECTIONDETAIL - PARALLEL TO JOIST AT ROOF3TYPICAL NON-LOAD BEARING JOIST CONNECTION

DETAIL- PERPENDICULAR TO JOIST AT ROOF2TYPICAL JOIST BEARING CONNECTION DETAIL1

TYPICAL FOUNDATION DETAIL4 TYPICAL FOUNDATION DETAIL5

STRUCTURAL DETAILS

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© Oldcastle PrecastTYPICAL MITER CORNER CONNECTION DETAIL3

PANEL-TO-PANEL SHEAR CONNECTION DETAIL1 TYPICAL MID-SPAN CONNECTION DETAIL2

TYPICAL BUTT-END CORNER CONNECTION DETAIL4

STRUCTURAL DETAILS AS.5

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SUSTAINABLE DESIGN

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© Oldcastle PrecastSD.1

SUSTAINABLE DESIGN & DEVELOPMENT

SUSTAINABILITY

The responsible management of energy andenvironmental resources is the greatest challengein the building industry. Labels such as“environmentally friendly” or “green” are not justcatchy marketing phrases at Oldcastle. We believein maximizing opportunities for long-termsustainable development with our products.

The Oldcastle Precast Wall Panel System helpsowners and designers to achieve the highest levelsof sustainable building design. From manufacturingto completion the Oldcastle team creates projectsthat are designed for:

Resource EfficiencyEnergy EfficiencyHuman ComfortLEED™ Certification

RESOURCE EFFICIENCY

Sustainable properties of precast concrete includethe following:

• Resource EfficientConcrete is made from three of the earth’s mostabundant resources:o Watero Stone, sand and gravel aggregateso Cement which is predominantly limestone,

the most abundant mineral on earth

• Recycled ProductsPrecast concrete typically includes recycledcomponents such as fly ash, slag cement, andsilica fume, all waste by-products from powerplants, steel mills, and other manufacturingfacilities.

• Ecologically PreferableCompared to logging for wood products and ironore mining for steel production, the extractionfrom the earth of aggregate and limestone is theleast disruptive to land and the fragile ecologythat it supports; and aggregate and limestonequarries can be restored to nature reserves, parksand other recreational, commercial or residentialuses.

• Highly DurableConcrete actually gets stronger with age. It cantake years, even decades, for concrete to fullyhydrate and reach its highest strength. ThePantheon in Rome, a concrete building circa 180a.d., is still in use. The longer the life span ofthe building, the more sustainable benefit it has.

• Minimizes WasteBy creating products that are built at the factoryto the exact sizes required, concrete minimizesconstruction waste.

• RecyclableConcrete can be crushed and reused as aggregatein new concrete mixtures particularly forinfrastructure projects such as roads, sidewalks,and bridges, as well as for environmental erosioncontrol. The ASTM definition of coarse aggregateincludes crushed concrete, and the definition ofmanufactured sand includes crushed concretefines. The U.S. Army Corps of Engineers and theFederal Highway Commission encourage the useof recycled concrete for their projects.Furthermore, the steel used for its reinforcement,normally obtained from recycled steel, can berecycled again.

• Resourceful Finish OptionsConcrete, without any applied finish is a beautiful,natural looking product, particularly when welldesigned with reveals to create architecturalinterest. Also, reusable formliners can be usedto create finishes of concrete surfaces to exposethe natural beauty of concrete.

Thin Brick embedded on precast panels is anenergy efficient solution to all masonry projects.The raw clay materials, fuels used formanufacturing and shipping are about seventy-five percent less than those used in full-bed-depthbrick projects. Furthermore, precast panels withembedded brick do not require sources of energyloss such as the weep holes and air space requiredin conventional masonry construction.

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ENERGY EFFICIENCY

Well-informed building owners look for bottom-linesavings in energy efficient building design andtechnologies. Exterior wall system selection is keyto creating energy efficient buildings.

Oldcastle’s CarbonCast® precast concrete sandwichwall panels, consisting of an exterior wythe ofconcrete (typically 2-1/2” thick), an inner layer ofcontinuous rigid insulation, and an interior wytheof concrete (typically 2” thick), are an ideal productfor energy conservation. The concrete walls includethermal mass properties that absorb and retain heatand the insulation provides low thermal conductivity(high R-value).

• Air Leakage ControlAir leakage is one of the greatest areas of heatand energy loss. Air leakage typically occursaround windows, doors and building joints.Precast concrete wall panels are extremelyefficient at reducing potential sources of airleakage because there are few joints; andconcrete has excellent characteristics forpreventing the passage of air and moisture.

• Reducing Solar Heat GainSolar heat gain contributes to the need for highcooling loads, one of the greatest consumers ofenergy. The higher the solar gain, the greaterthe energy consumption. Building orientation,shading devices, and light reflectance can helpto control the amount of solar gain.

The orientation of a building on the sitecontributes heavily to its ability to offset solargain. Rectangular buildings placed in an east-west orientation will have the least amount ofglazing in the direction of the morning andafternoon sun and the most amount of glazingon the north and south facades. The north façadereceives very little sun and the south face can becontrolled with shading devices and, to someextent, solar control glass. Oldcastle Glass®,www.oldcastleglass.com, can provide additionalinformation on the variety of best glass choicesthat contribute to the sustainable aspects ofdesign.

Precast concrete also is generally a light color(high-albedo) which helps to reflect solarradiation to reduce cooling loads. Dark coloredmaterials such as roofs, paving and walls causean effect called “heat islands,” a growing concernin urban and suburban areas where temperaturesare higher than rural areas because the surfacescapture solar gain. Light-colored precast concreteroof pavers, and roof garden waterproofingsystems are products available from Oldcastle tohelp reduce the “heat island” effect.

• Lighting and DaylightingThrough proper design, including glass selectionand shading devices, natural light from windows(“daylighting”) can be used to significantly reducethe amount of artificial lighting. Effectivedaylighting and energy efficient light fixtures andcontrols can help to significantly reduce buildingenergy costs.

• Thermal Mass BenefitsThermal mass is the property of a buildingmaterial to store and over time release heat.Concrete, with its high thermal mass, is able tostore large quantities of heat. Early civilizationssuch as the American Southwest Indians tookadvantage of thermal mass by using thick adobewalls to keep their homes cool during the dayand warm at night.

Today, however, thermal mass and its effect onenergy performance is one of the mostcontroversial issues facing designers, owners andmanufacturers. Some manufacturers claim high“mass-enhanced” R-values exceeding normal“steady state” R-values by wide amounts;however, the only way to measure the effect ofthermal mass is through rigorous computercalculations taking into account precise buildinglocation, orientation, climate and other variables.Clear definitions and standards are needed.

R-Values Defined

R-value: R-value is “resistance” to heat flow. Thehigher the R-value of a wall, the better it is atresisting heat loss or heat gain. Published R-valuesof various building materials are based on steadystate laboratory tests.

Steady State R-value: R-values are measured intesting laboratories in a “guarded hot box” whereone side of the material is kept at a steady warmtemperature and measurements are taken of howmuch energy is required to keep the other side at asteady cooler temperature. The amount of energythat passes through the material is measured asBTU/sq.ft.hr°F. R-value is the resistance of thematerial to the passing of that energy. Concretehas an R-value of .06/inch; insulation R-values varyfrom 3.0/inch to 8.2/inch.

Mass-Enhanced R-value: Sometimes referred toas “effective” R-value, mass-enhanced R-valuerefers to the ability of high-mass materials, suchas concrete, to achieve better energy performanceover time than would be expected by simply usingpublished steady state R-values. Sophisticatedcomputer software such as DOE-2 or BLAST is usedto analyze the effect of thermal mass over longperiods of time; however, the actual performanceis highly dependent on building location and, inparticular, climate. This makes national publicationof mass-enhanced R-values difficult at best andunreliable at worst.

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When and Where is Thermal Mass MostEffective?

Energy is conserved the most when there aresignificant changes in heat flow during the day. Forexample, in climates where there are large dailytemperature swings, exterior walls are heatedduring the day and cooled at night. When theoutdoor temperatures are warm during the day, theinterior surface of the walls remain relatively coolbecause the heat does not rapidly penetrate aconcrete mass. When the outside temperatureswings to nighttime cooling, the concrete mass isslowly cooled by releasing the heat retained duringthe day creating a thermal lag. The effect of thisis:

• Reduction of heating and cooling loads forless energy consumption.

• Reduction in size of heating and coolingequipment required.

• Reduction of peak hour heating and coolingloads allowing off-peak energy usage whenrates are lowest.

Although the thermal mass of concrete is beneficialin most U.S. climates, the greatest benefits occurin the southwest regions where daily temperatureswings are largest, particularly in the fall and springmonths. At the other extreme, such as Alaska,where 24-hour outside winter temperatures are wellbelow indoor temperatures, mass has little or noeffect on R-value performance.

Based upon a study conducted by the masonryindustry comparing theoretical thermal massbenefits of various U.S. regions, and documentedin an article by Martin McBride for The ConstructionSpecifier, the thermal mass benefit is evident innortheast climates, though significantly lower incomparison to southwest regions.

Thermal Mass Benefits of the Oldcastle PrecastWall System

Simply put, there is no other precast concrete wallsystem on the market that surpasses the thermalmass potential of the Oldcastle Precast Wall System.The system contains the five most importantcomponents of a successful thermal mass assembly:

• High Heat Capacity – Heat capacity (HC) isthe amount of heat necessary to raise thetemperature of a given mass 1°F. HC is usedin energy codes to determine when a wallhas enough thermal mass to use “masscriteria” or “mass credit” as a means fordetermining R-value. ANSI/ASHRAE/IESNAStandard 90-1-2007, the standard referredto by many energy codes, defines “mass wall”as a wall with an HC exceeding 7 BTU/sq.ft.°F; the concrete in a typicalCarbonCast® wall has an HC of 10.8,qualifying it for thermal mass creditcalculation.

• Low thermal conductivity – The rigidinsulation placed in the middle of twoseparate concrete wythes assists the concreteto retain its collected heat by effectivelyreducing unwanted heat transfer, an optimumcombination of two materials workingtogether.

• Continuous Insulation – ASHRAE 90-1-2007requires that a “mass wall” have “continuousinsulation across all structural memberswithout thermal bridges…,” just as theCarbonCast® wall system is designed.

• No thermal bridge – The two wythes ofconcrete are connected together using apatented high strength “shear grid” consistingof thermally low conductive carbon fiber tovirtually eliminate any thermal bridge.

• Inner Surface of Concrete – The thermalmass of concrete works best when the massis exposed on the inside surface of the wall,as in the two-wythe Oldcastle system.

Thermal Mass Summary

The Oldcastle precast walls contain the beneficialproperties of a highly effective thermal masssystem; nevertheless, there is need for industry-wide nationally recognized and standardized testingto quantify expected energy performance. AlexWilson, executive editor of Environmental BuildingNews and former executive director of the NortheastSustainable Energy Association summarizes thebenefits of high-mass building materials as “highlydependent upon where the building is located, howit is designed, and how it is operated. How we shouldgive credit — in terms of energy performance —for high-mass building materials is still very muchopen for debate. Until standardized procedures fordetermining the regional significance of the masseffect are widely applied, there will likely becontinued confusion and continued exaggerationregarding the energy benefits of thermal mass.” Agreat deal of work remains to be done to standardizethe measurements of the beneficial effects ofthermal mass. Oldcastle supports efforts of someof the nation’s leading researchers, including OakRidge National Laboratory, to bring these issues intopublic awareness.

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HUMAN COMFORT

• Excellent Indoor Air QualityThe quality of the indoor air is crucial to the well-being of the occupants. Building owners andoccupants are increasingly demanding “green”buildings that minimize the type of pollutants thatlead to “sick building syndrome.”

Precast concrete has extremely low emissions ofthe type of off-gassing substances that plaguemany buildings with “sick syndrome.” Precastconcrete is also one of the best building materialsavailable to inhibit or prevent mold growth.Concrete is non-organic and mold requires moistorganic nutrients to grow. Furthermore, the lowpermeability rating of precast concrete inhibitsthe penetration of mold spores from the exterior.

Concrete alone cannot achieve goals of reducingindoor air pollutants. Designers must carefullychoose low volatile organic compounds (VOC)materials such as carpet, partitions and paint;and engineers must carefully design themechanical systems for appropriate levels ofventilation and air circulation. But, in conjunctionwith these design choices, precast concrete is byfar the best building material to achieve beneficialindoor air quality.

LEED™CERTIFICATION

The Leadership in Energy and Environmental Design(LEED) green building rating system is administeredby the U.S. Green Building Council (USGBC), acoalition of building industry leaders working topromote buildings that are environmentallyresponsible, profitable and healthy places to liveand work.

LEED certification is typically voluntary, yet thereare increasing numbers of tax benefits and/or grantsbeing offered for green buildings. Many U.S.government agencies and some states and localitiesare mandating that LEED requirements be met, andsome are even requiring LEED certification for publicbuildings.

While civic pride for building “green” can bring somesatisfaction to building owners, tangible economicbenefits that come from certification will generatethe most enthusiasm. For example, meeting manyof the green building practices that lead to LEEDcertification can result in energy and cost savingsover the life of the building. Furthermore, workersin LEED certified environments can have increasedproductivity translating directly into companyprofits.

The LEED rating system divides credits andprerequisites into five categories:

• Sustainable Sites• Water Efficiency• Energy & Atmosphere• Indoor Environmental Quality• Innovation and Design Process

Prerequisites and credits are based mostly onestablished governmental or trade group standards.The number of points a project earns determinesthe level at which a project can be certified. Thecertification levels are Platinum, Gold, Silver andCertified.

The Oldcastle Precast Wall Panel System can helpowners and designers achieve LEED certification.Compliance with LEED prerequisites and obtainingLEED credits can be obtained through:

• Use of Recycled ContentThis credit is for projects that “use materials withrecycled content such that the sum of post-consumer recycled content plus one-half of thepre-consumer content constitutes at least 10%of the total value of the materials in the project.”Supplementary cementitious materials, such asfly ash, silica fume, and slag cement, areconsidered pre-consumer. Recycled concrete orslag as aggregates qualifies as post-consumer.

• Optimizing Energy PerformanceThis credit is allowed if energy cost savings canbe shown compared to a base building that meetsthe requirements of ASHRAE 90-1-2007.Oldcastle’s precast concrete wall system, with

high insulation value, high thermal mass , andlow infiltration, for example are benefits increating energy cost savings.

• Use of Regionally Produced ConcreteProductsOldcastle has plants in most U.S. regions to meetthe requirement to “use building materials orproducts that have been extracted, harvested orrecovered, as well as manufactured, within 500miles of the project site for a minimum 10% ofthe total materials value.”

• Having a LEED Accredited Professional creditis given if a LEED Accredited Professioanl is partof the project team. Oldcastle’s team of engineersincludes LEED Accredited Professionals.

For an excellent discussion on how to achieveLEED certification through the use of precastconcrete products, see “Achieving Sustainabilitywith Precast Concrete,” by Martha VanGeem, P.E.,LEED A.P., in PCI Journal, Jan., Feb. 2006.

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CASE STUDIES

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Project Description - This 983,000 SF in-dustrial warehouse complex has 36 foot clear ceil-ing heights, 196 loading doors arranged in a crossdock format and 4 drive in doors. The permiter loadbearing insulated wall panels have embedded bear-ing seats for bar joist and joist girders, eliminatinginterior perimeter steel.

II. Project Team -Owner/CM/Contractor:

Greenfield Builders, Inc. Indianapolis, INArchitects:

MH ArchitecturePrecaster and Precast Specialty Engineers:

Oldcastle Precast Building Systems

III.

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Major Features -CarbonCast® Industrial Wall Panels• 293,000 Square Feet of Precast Wall Panel• 538 Precast Concrete pieces• 12’-0” wide panels, typical• 46’-6” tall panels, typical• 10” thick wall panels• R-20 insulation• Erected in 30 days• Steel Form Finish (smooth)

CS.A1

ALOVATS ‘A’ & ‘B’Monroe, New Jersey

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ADVENTUREAQUARIUMCamden, New Jersey

Project Description - This new structure isan expansion building to the existing aquarium andaccommodates three new exhibits, a main entryatrium, a new food service area, gift shop and res-taurant. The new exhibits include the “West AfricanRiver Experience”, the “Jules Verne Gallery” and the550,000 gallon Shark Realm tank.

II. Project Team -Owner: State of New JerseyContractor:

Whiting-Turner Contracting, Co., Towson, MDArchitects:

Granary Associates, Philadelphia, PAPrecaster and Precast Specialty Engineers:


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Major Features -CarbonCast® Industrial Insulated Wall Panels• 38,000 Square Feet of Precast Wall Panel• Load and Non-Load Bearing Panels• 41’-0” tall panels, typical• 10” thick wall panels• R-16 wall insulation• Steel form finish with reveals (painted)

CS.B1

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STEINER STUDIOSBrooklyn Navy Yard, New York

Project Description - 270,000 SF state-of-the-art film studio and production facility with 5sound stages with up to 45 foot ceiling heights, a 3-story office complex, screening rooms and othersupport facilities.

II. Project Team -Owner:

Steiner Equities Group, New York, NYGeneral Contractor:

Steiner Building Co., New York, NYArchitects:

Richard Dattner & Partners Architects PCNew York, NY (building exterior)

Precaster:Oldcastle Precast Building Systems

III.

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Major Features -Total Precast Concrete Structure• Exterior Load and Non-Load Bearing Panels• Interior Load Bearing Panels• Hollow Core Plank• Beams and Columns• Stairs and Landings• Erected in 30 days• 1,957 Precast Pieces

133,500 s.f. of 12” hollowcore plank (553 pcs)109,800 s.f. of 8” wall panels (586 pcs)9,100 l.f. of columns and beams (366 pcs)102,300 s.f. of 12” wall panels (360 pcs)92 stair and landing pieces

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CS.C1

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REFERENCES & RESOURCES

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REFERENCES &RESOURCES

RR.1

The following associations, organizations and agen-cies offer useful information on the wide range ofsubjects in precast concrete products and, in par-ticular, precast wall panels.


www.oldcastlesystems.com

Associations, Organizations, Agencies:AltusGroup – A partnership of precast industryproducers making precast innovations,particularly in carbon-fiber reinforced concrete,www.altusprecast.com.National Association of Industrial and Office ParkProperties, www.naiop.org – An association ofdevelopers, owners and professionals ofcommercial, industrial and mixed-use realestate.Precast Concrete Institute – www.pci.org.Portland Cement Organization –www.cement.org - a trade organizationrepresenting cement companies in the U.S. andCanada.United States Green Building Council (USGBC)– a non-profit coalition of trade members anddevelopers of high-performance green buildingdesign through LEED (Leadership in Energy andEnvironmental Design), www.usgbc.org.

Books, Articles and On-line Resources:

“Some Aspects of Sustainability,” Adam Neville,D.Sc., PCI Journal, January-February, 2006, pp.72-75.“Achieving Sustainability With Precast Concrete,”Martha Van Geem, P.E., LEED A.P., PCI Journal,January-February, 2006, pp. 42-61.World Commission on Environment andDevelopment, “Report on Our Common Future,”Oxford University Press, New York, NY, 1987.

www.concretethinker.com - a Portland CementAssociation (www.cement.org) web site resourcefor sustainability design issues.“LEED Reference Guide,” Ready Mixed ConcreteIndustry, RMC Research Foundation, 2006,www.rmc-foundation.org.National Conference of States on Building Codesand Standards, Inc., Directory of Building andCode Regulations, www.ncsbcs.org.Energy Efficient and Renewable Energy Network,www.eren.doe.gov.LEED Green Building Rating System,www.usgbc.org/programs/leed.htm.U.S. Green Building Council, 2002, LEED for NewConstruction and Major Renovations, LEED-NCVersion 2.1 Reference Package, Washington,D.C., U.S. Green Building Council.“Exceptional Industrial Projects: Beyond TheBox,” National Association of Industrial and OfficeProperties, 2003.“Rules of Thumb for Distribution/WarehouseFacilities Design,” National Association ofIndustrial and Office Park Properties, 2005.“Oldcastle Residential Building System,” EquusDesign Group, Oldcastle Precast BuildingSystems, 2006.“Oldcastle Office Building System,” Equus DesignGroup, Oldcastle Precast Building Systems,2006.“State-of-the-Art of Precast/PrestressedSandwich Wall Panels, PCI Journal, March/April,1997.“Architectural Precast Concrete,” Precast/Prestressed Concrete Institute, Third Edition,2007.“Designing with Precast and PrestressedConcrete, Precast/Prestressed ConcreteInstitute, a looseleaf manual available from PCI.Architectural Precast Concrete Color and TextureSelection Guide, 2nd Edition, PCI, 2003.

Articles and Resources on Sustainability:

• “Thermal Mass Credits for Commercial BuildingWalls,” Merle F. McBride, The ConstructionSpecifier.

• “Thermal Mass – The Energy Saver in Concreteand Masonry Buildings,” Environmental Councilof Concrete Organizations.

• “Thermal Mass and R-Value: Making Sense of aConfusing Issue,” Alex Wilson, EnvironmentalBuilding News, April 1, 1998.

• “Thermal Mass,” ConcreteThinker.com, PortlandCement Association.

• Martha G. VanGeem, P.E., Designers Notebook,“Energy Conservation,” Precast/PrestressedConcrete Institute.

• ANSI/ASHRAE/IESNA Standard 90-1-2007,Energy Standard for Buildings Except Low-riseResidential Buildings, 2007.

• “Passive Solar Design,” U.S. Department ofEnergy – Energy Efficiency and RenewableEnergy, eere.energy.gov.

• “Achieving Sustainability with Precast Concrete,”Martha VanGeem, P.E., LEED A.P., PCI Journal,Jan., Feb. 2006.

“Guide for Precast Concrete Wall Panels,” ACI533R-93 (Reapproved 2004), American ConcreteInstitute.“Total Precast Concrete Structures,” CanadianPrecast/Prestressed Concrete Institute.“Architectural Precast Concrete: Walls andStructure, Best Practice Guide,” CanadaMortgage and Housing Corporation, 2002.

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PHOTO & IMAGECREDITS

RR.2

Table of Contents1. AltusGroup, Inc.2-4. Oldcastle Precast, Inc.

OP.1 1. AltusGroup, Inc.2. AltusGroup, Inc.

OP.3 1. Precast/Prestressed Concrete Institute 2. Environment Council of Concrete

Organizations3. Oldcastle Precast, Inc.

OP.4 Oldcastle Precast, Inc.WP.0 1. Oldcastle Precast, Inc.

2. Oldcastle Precast, Inc.3. Equus Design Group, Inc.4. Oldcastle Precast, Inc.

WP.1 1-7. Oldcastle Precast, Inc.8. Metromont Corp.9. Oldcastle Precast, Inc.10. Equus Design Group, Inc.

WP.2 Oldcastle Precast, Inc.WP.3 Oldcastle Precast, Inc.WP.4 Oldcastle Precast, Inc.WP.5 Equus Design Group, Inc.WP.6 Metromont Corp.WP.7 1. Oldcastle Precast, Inc.

2. Metromont Corp.3-5. Oldcastle Precast, Inc.6. Equus Design Group, Inc.7. Oldcastle Precast, Inc.

WP.8 Oldcastle Precast, Inc.WP.9 Oldcastle Precast, Inc.WP.10 Metromont Corp.WP.11 1. Equus Design Group, Inc.

2. Metromont Corp.3-6. Equus Design Group, Inc.

DG.0 Oldcastle Precast, Inc.DG.1 1. Oldcastle Precast, Inc.

2. AltusGroup, Inc..DG.2 1. Oldcastle Precast, Inc.

2. Oldcastle Precast, Inc.3. AltusGroup, Inc.4. Equus Design Group, Inc.

DG.3 Equus Design Group, Inc.

DG.4 Oldcastle Precast, Inc.DG.5 Equus Design Group, Inc.DG.6 Oldcastle Precast, Inc.DG.7 Photos - Oldcastle Precast, Inc.

Images - Equus Design Group, Inc.DG.8 Oldcastle Precast, Inc.DG.9 1. Oldcastle Precast, Inc.

2. Oldcastle Precast, Inc.3. Equus Design Group, Inc.4. Oldcastle Precast, Inc.

DG.10 1. Oldcastle Precast, Inc.2. Oldcastle Precast, Inc.3. Equus Design Group, Inc.

DG.11 Equus Design Group, Inc.DG.12 Oldcastle Precast, Inc.DG.13 1. Equus Design Group, Inc.

2. Oldcastle Precast, Inc.DG.14 Oldcastle Precast, Inc.DG.15 Oldcastle Precast, Inc.DG.16 Oldcastle Precast, Inc.DG.17 Precast/Prestressed Concrete InstituteDG.18 Formliners - Scott System, Inc.

Thin Brick - Glen-Gery Corp.IronRock Capital, Inc.Summitville Tiles, Inc.

AS.1 Equus Design Group, Inc.AS.2 Equus Design Group, Inc.AS.3 Equus Design Group, Inc.AS.4 Equus Design Group, Inc.AS.5 Equus Design Group, Inc.SD.1 AltusGroup, Inc.SD.2 Equus Design Group, Inc.SD.3 Public Domain - Wikipedia.comSD.4 NASACS.A1 Oldcastle Precast, Inc.CS.B1 Oldcastle Precast, Inc.CS.C1 Oldcastle Precast, Inc.

Note: All photos and images on page by companystated, unless noted otherwise.

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