Ultra-High Performance Wall System

We are your wall—one system, one supplier, one warranty. Our Ultra-High Performance Wall System (UHPWS) is a prefabricated unitized wall system that combines Glass Fiber Reinforced Concrete (GFRC), Schüco windows, mineral wool insulation and a sealed back pan into one integrated system. These wall systems are manufactured in our Orlando factory and are shipped to the jobsite as a finished wall.

Glass Fiber Reinforced Concrete

GFRC is a lightweight, impact resistant masonry cladding system made of galvanized steel framing and a GFRC skin of minimum 3/4” thickness. The GFRC skin is mechanically connected to galvanized steel framing with flexible anchors that allow for differential movement between the two components.

GFRC skin is made using Portland cement, sand, aggregate and alkali resistant glass fiber that has excellent flexural strength and impact resistance properties. Skin materials are sprayed by thin layers into molds. This makes GFRC highly effective at capturing complex geometries, deep returns and intricate ornamentation.

Description

Molds are usually produced with 5-axis CNC technology to maintain tight fabrication tolerances and efficiencies. Building Blocks works with architects and engineers in a digital design process that employs Revit, Rhino, and Grasshopper.

Once the GFRC component of the wall system is completed, the window is set and anchored to the GFRC framing. A two-stage sealant joint is then applied to the interface between the window and the GFRC. Building Blocks uses Schüco windows, which are German engineered and locally fabricated. They bring performance, reliability and durability to the fenestrations of our wall system.

The cavity space of the wall system is packed with either Thermafiber CW-90 mineral wool insulation or Thermafiber SAFB, for acoustical applications. Thermal insulating tape is applied to the backside of the framing as a thermal break.

18-gauge sheet metal is screwed to the framing. Sealant is applied to all penetrations through the back pan. The panels are hand finished and then shipped. The total system weighs between 12 to 22 lbs per SF based on the window to wall ratio.

GFRC skin with galvanized steel framing

ThermaFiber insultation and insulating tape

18-gauge sheet metal backpan with sealant

Panels of GFRC can be as large as 11’-6” by 38’-0” for a total surface area of 440 square feet. Panels are shipped to the jobsite on a flatbed truck. A typical load contains 1,500 to 2,500 square feet of material. Panels are erected with either a ground crane or tower crane at a rate of 1,500 to 2,000 square feet per day.

GFRC cladding is typically designed as horizontal panels that span floor to floor with gravity connections on one floor and lateral connections on the opposite floor. Panels can span multiple floor heights when the design allows vertical panels. Gravity connections are relatively lightweight due to the weight efficiency of GFRC with typical loads of 1,500 lbs per connection.

SMOKE SEAL2" MINERAL WOOL

INSULATION 4" DEEP MIN8" FLOOR SLAB

4" CW40 MINERAL WOOLINSULATION

FACTORY INSTALLED20GA AIR/VAPOR BARRIER FACTORY

INSTALLED

20GA AIR/VAPOR BARRIER FIELDINSTALLED

OVER 3M VR TAPEINTERIOR FINISH BY OTHERS

4" CW40 MINERAL WOOLINSULATION

FACTORY INSTALLED20GA AIR/VAPOR BARRIER

FACTORY INSTALLED

20GA AIR/VAPOR BARRIERFIELD INSTALLEDOVER 3M VR TAPE

INTERIOR FINISH BY OTHERS

FIRE SAFING OMITTEDFOR CLARITY SEE DETAIL 1

FOR ADDITIONAL NOTESBLOCK OUT BOX PROVIDED

ATCONNECTION POINTS

FIELD FILL POCKETS AFTERALIGNMENT

Application

Finishes

GFRC can be produced in a wide variety of colors, textures and patterns. Colors are achieved from a combination of through-body pigmentation, aggregates, surface stains and coatings.

Most colors that are incorporated into the body of GFRC are synthetic mineral-oxide pigments. Naturally colored aggregates are used separately or in combination with pigments to arrive at a desired color.

Bright and highly saturated colors are accomplished with masonry stains and sealers. These finishes can be made to have a matte, shiny, metallic, shimmer or glitter effect.

Texture is achieved by sandblasting the surface. Sandblasting can be done with fine grade particles and lightly applied for a smooth form finish, through five progressive stages, to large particles, heavily applied for a course finish.

Patterns and intricate designs are made by using a formliner set into the mold. Due to the richness of cement in the face mix, GFRC captures and retains crisp details.

Flexibility in form, texture and color.

Performance

Thermal

Curtainwall Design Consulting performed a thermal modeling study of a Building Blocks prefabricated unitized wall system for a project in Blackhawk, Colorado. Testing parameters were 95-degree temperature gradient between interior and exterior with a 30% interior relative humidity. Interior dew point was calculated to be 41-degree F. The coldest interior surface of the wall modeled to 66.6-degree F.

Acoustical

Curtainwall Design Consulting also performed an acoustical model of a Building Blocks prefabricated unitized wall system that utilized Thermafiber Sound Attenuation Fire Blanket (SAFB) to increase the acoustical performance. The wall assembly modeled to an OITC rating of 76 and an STC rating of 93.

Fire

GFRC with a steel stud frame has been tested to show a 0 Flame Spread and 5 Smoke Development Index. It passes as a 2-hour fire rated wall with the addition of ½” drywall on the framing and mineral wool insulation. The National Fire Protection Agency tested a GFRC wall assembly with mineral wool at all panel joints. It passed the NFPA 285 Standard Fire Test Method for Evaluation of Fire Propagation Characteristics of Exterior Non-Load-Bearing Wall Assemblies Containing Combustible Components.

Single Source

Building Blocks provides a single source for your project’s entire vertical envelope. We combine best in class means, methods and materials to deliver a truly Ultra-High Performance Wall System. This allows us to provide a 7 year warranty, which is extendable to 10 years with a maintenance contract.

Building Blocks is a member of the Precast Prestressed Concrete Institute (PCI). The PCI certification process is a

Quality Assurance

Building Blocks is a furnish and install subcontractor. We take your project from start to finish, from the design and engineering through the fabrication and installation. Our GFRC manufacturing facility is located in Orlando, Florida and ships to all states east of the continental divide.

Technical Data

Property Test Result

Air Leakage* ASTM E283 Static Air Infiltration at 6.24 PSF = 0.02 CFM/SFStatic Air Exfiltration at 6.24 PSF = 0.03 CFM/SF

Structural Design Performance ASTM E330 -+45/-45 PSF deflection was less than L/175-+67/-67 PSF permanent deformation was less than L/1000

Static Pressure Water Resistance* ASTM E331 Static Water Infiltration at 10.0 PSF = 0

Dynamic Pressure Water Resistance AAMA 501 Dynamic Water Infiltration at 100.0 MPH = 0

Thermal Transmittance Resistance AAMA 1503 -20°F (exterior), 75°F (interior), 30% RH = 0 condensation

Glass Fiber Content ASTM C1229 Glass Fiber 5% by weight

Flexural Strength ASTM C947 1,200 PSI

Compressive Strength ASTM C39 10,000 PSI

Coefficient of Linear Thermal Expansion ASTM E381 7.6 x 10-6 in/in/ºF (13.6 x 10-6 mm/mm/°C)

Water Vapor Transmission ASTM E96 1.5 Perm with Mineral Wool0.1 Perm with Closed Cell Foam Insulation

Surface Burn Characteristics ASTM E84 0 Flame Spread5 Smoke Development

Materials in a Tube Furnace ASTM E136 Noncombustible

*Results dependent on window design

comprehensive quality assurance program that oversees the design, engineering, fabrication and erection of GFRC.

The PCI certification program was developed and is updated by a team respresenting all industry stakeholders. The program is backed by PCI and its network of committees, research and development, education, codes and standards, programs, and relationships in the industry.

Working with Building Blocks ensures the knowledge and experience necessary to deliver a premium product with a history of quality assurance since our inception in 1983.