new two-story, 50,000 ft2 (4600 m2) commercial office
building that captured the essence of Neo-French
Classical architecture while staying within a fixed market rate cost for this type of structure. The precaster was brought in at an early design stage to work with the architect and owner to develop a very detailed, typical selfsupporting wall panel 10 ft (3 m) wide x 34 ft (10.4 m) high. Great care was taken to build a mold that could be used over and over again, but would give the project a wonderful sense of detail and richness (Fig. 2.1.5[b] and [c]). Because of the repetitive nature of the panels and their ease of installation, the precast concrete system ended up costing less than brick and steel construction. The result of using this architectural precast concrete system was a beautifully detailed Class A office building that was 90% leased within four months. Coordinated design, complete dimensioning, and clear specifications (see Chapter 6) are also important factors in obtaining optimum quality and economy using architectural precast concrete. In the preparation of the contract documents, the selection and description of materials and performance requirements should be clearly stated. They should not be left open to variable interpretations, however nor should they be overly restrictive. The contract documents should make reference to the PCI Manual for Quality Control for Plants and Production of Architectural Precast Concrete Products (MNL-117), which includes Category A-1 certification of the production facility, as the industry guideline for production of architectural precast concrete elements. Exceptions to this standard or specific requirements should be clearly set forth in the contract documents. 2.2 DESIGN ECONOMY Understanding architectural precast costs is essential to designing affordable faades that enhance the overall building design while meeting the owner s budget. Understanding the architectural precast concrete manufacturing process can help achieve design goals and control costs. During a project s conceptual stage, the designer has many variables to consider that affect precast concrete cost. A local precaster can assist with preliminary design and budget estimating early in the project s design phase. Piece size and repetition typically have the most significant cost impacts. In addition, material selection, textures, surface geometry, cross-section, erection details,
jobsite access conditions, and connections can
affect cost. The custom, sculptured designs that are possible with precast concrete may be achieved within a limited budget by selecting appropriate aggregates and textures combined with repetitive units and efficient production and erection details. Input from the precaster can be beneficial in developing options for creating an economical design that also satisfies the designer s aesthetic requirements. During preliminary design, a precast concrete project can be preliminarly budgeted on a square-foot (m2) basis. Although this provides a starting point, it is recommended that the designer seek additional estimating assistance from a precaster. Working with a precaster on a specific project will help determine a final budget that is more accurate than a ballpark price per square foot (m2). A cost per square foot (m2) can be misleading to general contractors and architects because square foot (m2) quantities are calculated differently from precaster to precaster depending on the take-off procedures. Also, total work scope requirements such as site restrictions, work scope inclusions, and detail manufacturing requirements are initially unknown. Budget pricing from local precasters, submitted in writing and including assumptions, will aid design efforts from schematic design through final contract documents. As a project evolves from preliminary sketches through working drawings, the precaster(s) should be informed of all changes. Pricing accuracy depends on the information provided to the precaster s estimator. This discussion on design economy uses square foot (m2) prices to describe a designer s precast concrete options. All prices are for relative comparison only and should not be used to make decisions for individual projects. The design and detailing of the precast concrete units should reflect good production concepts. Consultation with a precaster at an early stage will be helpful. The designer needs to define the shape of the units and their appearance. 2.2.1 Repetition A key element to cost-effective production is minimizing the number of molds and mold changes, and maximizing the number of castings from each mold, particularly if the molds have shape. Efficiency and economy are achieved by making it possible for similar, if not identical, shapes to be produced from the same basic (master) mold, and by minimizing the time required to disassemble a mold and reassemble it for the manufacture of the next piece. Figure 2.2.1(a) shows the master mold for the production of the arch member panels for the project in Fig. 3.3.18(a), page 121. The largest segment of the arch is shown in Fig. 2.2.1(b). Careful planning is necessary to achieve good repetition in the design without sacrificing design freedom. For example, many design variations may be developed by incorporating two basic architectural panel types (spandrel panels and floor-to-floor panels with