CALIFORNIA

COLORADO

WallPanelDesignManual GEORGIA

OREGON

UTAH

WASHINGTON

ProvidingEngineeredConcreteSolutions


Copyright©2010
ByEnConDesign,LLC
WPM001
11.23.2010Rev1
Introduction
 SandCreekHighSchool
Precast concrete wall panels are an extremely versatile
product.  They have the capability to be an integral
componentofatraditionalbuildingsystemaswellaspart
of an entire precast concrete building system.  This Wall
PanelSystemsDesignManualprovidesinformationabout
the various types of precast wall panels and building
systems that are available from EnCon Companies, and
the ways each system is best used. Owners, contractors,
architects,andengineerswilldiscoverthatwallpanelscan
functioninawidevarietyofsettingsandofferamyriadof
benefits. A few of the countless benefits include the
economical, environmentally friendly, and timely
constructioncomparedtotraditionalbuildingmethods. ColoradoSpringsAirport

Every segment of the construction industry can benefit
from the high performance of precast concrete wall
panels.Theyareanenergysaving,resilient,andeasyto
maintain building envelope that require minimal upkeep.
Inaddition,theyprovideafinishedinteriorhardwalland
eliminate the need for exterior columns for support.
Precast wall panels can be rapidly constructed, are fire
resistant,moldandmildewresistant,anddecreasesound
transmission. They also meet unique building needs and
challenges, and offer unrivaled design flexibility in every
area including shape, style, finish, color, texture, and
decorativeornamentation.Thus,whenlowbuildingcosts,
reduced energy expenditure, minimal maitenence, long
term durability, and minimal fire insurance rates are
important,aprecastwallpanelsystemistheidealbuilding
arrangementforanystructure,whetheritbealow,mid,
or highrise edifice.  Regardless of the type of design,
EnCon’s precast concrete wall panels and wall panel
TheShopsatWalnutCreek
building systems provide owners, designers, and
contractorswithbenefitsthatareunsurpassed.

The following information includes sections that address
frequently asked questions and technical data, as well as
product cross section details and connection concepts.
Also enclosed are sample specifications and a set of
typical general notes.  For further information, or to
discuss a project, please see the contact list on the back
coverofthismanual.


1






2
TableofContents
Introduction................................................................................................................................................................................................1
TableofContents........................................................................................................................................................................................3
BenefitsoverotherConstructionMaterials...............................................................................................................................................5
ProductSystemUse....................................................................................................................................................................................5
Residential:SingleFamily,MultiFamily,MultipleUnit.........................................................................................................................5
Retail......................................................................................................................................................................................................5
Education...............................................................................................................................................................................................6
Commercial/Warehouse/Manufacturing...............................................................................................................................................6
Office......................................................................................................................................................................................................6
Religious.................................................................................................................................................................................................7
SecureEnvironments:FoodIndustry,Medical/LaboratoryFacilities.....................................................................................................7
JudicialandMilitary...............................................................................................................................................................................7
ProductVariations......................................................................................................................................................................................8
ManufacturingTolerances.....................................................................................................................................................................8
Color.......................................................................................................................................................................................................8
Finish......................................................................................................................................................................................................8
ThermalEfficiency..................................................................................................................................................................................8
Loadbearingvs.NonLoadbearing(Gravity)...........................................................................................................................................9
TypicalCombinations.............................................................................................................................................................................9
IndustrialGradeWall........................................................................................................................................................................9
StructuralPlus...................................................................................................................................................................................9
HighEndArchitectural......................................................................................................................................................................9
ProductTypes...........................................................................................................................................................................................10
ShearWalls..........................................................................................................................................................................................10
ColumnCover.......................................................................................................................................................................................10
Spandrels.............................................................................................................................................................................................10
Mullions...............................................................................................................................................................................................10
TrussWall.............................................................................................................................................................................................10
TrussWallAdvantages....................................................................................................................................................................10
CarbonCast®.........................................................................................................................................................................................11
CarbonCast®Advantages................................................................................................................................................................11
BuildingSystemVariations.......................................................................................................................................................................11
EnvelopeSystems................................................................................................................................................................................11
LoadbearingSystems...........................................................................................................................................................................11
LateralForceResistingSystems,eitherLoadbearingorNonLoadbearing..........................................................................................12
ArchitecturalEnhancementPanels......................................................................................................................................................12
ProductSystemBenefits...........................................................................................................................................................................12
AdvantagesofanEnConPrecastWallPanelSystem...........................................................................................................................12
Precastvs.EIFS.........................................................................................................................................................................................15
TypicalDesignandDeliveryProcess.........................................................................................................................................................16
EmbeddedBrick........................................................................................................................................................................................17
AdvantagesofEmbeddedBrickoverTraditionalMasonry..................................................................................................................17
OtherBenefitsInclude.........................................................................................................................................................................17
BrickPatterns.......................................................................................................................................................................................18
BrickSizes.............................................................................................................................................................................................18
RequirementsofEmbeddedBrickUnits..............................................................................................................................................19
ConsiderationswhenChoosingEmbeddedBrickWallPanels.............................................................................................................19
FrequentlyAskedQuestions.....................................................................................................................................................................20
WhatisaSandwichPanel?..................................................................................................................................................................20
WhatisaWythe?.................................................................................................................................................................................20
WhatisaWytheTie?...........................................................................................................................................................................20
WhatareRvalues?..............................................................................................................................................................................20
WhatisaThermalBridge?...................................................................................................................................................................21
WhatistheDifferencebetweenaCompositeandNonComposite?..................................................................................................22
WhatkindofInsulationisusedinInsulatedWallPanels?...................................................................................................................22
WhyareWytheTiesandSolidZonessoImportant?...........................................................................................................................22
HowthickistheamountofInsulationinthePanels?..........................................................................................................................23

3
 WhatsizePanelsareAvailable?..........................................................................................................................................................23
HowareWallPanelsProduced?..........................................................................................................................................................23
HowisaWallPanelSystemInstalled?................................................................................................................................................23
ArePrecastWallPanelsResistanttoAirBornDebris?........................................................................................................................24
WhataretheFinishOptions?..............................................................................................................................................................24
HowdoesBuildingwithPrecastConcreteContributetoLEED®Certification?...................................................................................25
WhatisthePCIPlantCertificationProgram?......................................................................................................................................27
CommonDetails.......................................................................................................................................................................................28
WalltoFoundation..............................................................................................................................................................................29
WalltoSlabonGradeatDockDoor....................................................................................................................................................29
ArchitecturalDetails............................................................................................................................................................................30
InsulationandBrickDetails.................................................................................................................................................................31
WallPaneltoWallPanelAlignment....................................................................................................................................................33
SpandreltoWallGravity......................................................................................................................................................................33
WallPaneltoWallPanelCorner..........................................................................................................................................................34
SteelBeamEmbedSupport.................................................................................................................................................................34
SteelJoistBearing................................................................................................................................................................................35
SteelJoistBearing(AlternativeView)..................................................................................................................................................35
SteelDeckSupport..............................................................................................................................................................................36
SteelBeamBearingPocket..................................................................................................................................................................36
DoubleTeeBearingPocket..................................................................................................................................................................37
DoubleTeeBearingwithoutPocket....................................................................................................................................................37
SamplesetofProjectSpecifications........................................................................................................................................................38
SamplesetofGeneralNotes....................................................................................................................................................................40

4
BenefitsoverotherConstructionMaterials
There are a variety of wall panel building systems on the market but none compare to or contain the benefits of
precast/prestressedconcrete.
 EnConPrecast TiltUp MetalPanel Masonry
WallSystems

DesignFlexibility X  X
Durability X X  X
LowLifeCycleCosts X 
LowMaintenance X X 
MoistureResistance X X 
PlantProductionforQualityAssurance X X
ThermalEfficiency X X 
YearRoundRapidConstruction X 
SecurityandSafety X X 
ProducedUnderaPlantCertificationProgram X 

ProductSystemUse
Residential:SingleFamily,MultiFamily,MultipleUnit SingleFamilyResidence
Precastwallstructuresaretheidealbuildingsystem.In
addition to their many benefits, they offer an average
reduction in heating and cooling costs of 50%. The
panelseliminateheattransfer,keepingwarmairinand
cold air out in the winter, and the opposite during the
summer months. The safety, security, and high fire
resistancepanelskeepinsurancerateslow.Wallpanels,
especially insulated panels, minimize noise between
units and help dampen noise outside of the structure.
Precast concrete also helps minimize mold, mildew, and other water related damage by providing superior moisture
controlandprotection.

Retail
Durable and easy to care for, wall panels are perfect for public spaces. A large
TheShopsatWalnutCreek varietyofsurfaceoptionsmake PikesPeakHarleyDavidson&Buell
precast wall panel systems especially wellsuited to retail centers
that desire a particular aesthetic appearance. The rapid
constructiontimeofawallpanelsystemminimizesinitialcostsand
enablespromptoccupancyandrevenuereturns.





5
Education
The finished and resilient interior and exterior surfaces of a precast wall system retains its excellent condition and
attractive appearance throughout the life of the structure. Energy efficient insulated panels eliminate the need for
additional insulation, air gaps, and thicker wall sections. Due to its high level of fireresistance, precast wall panels
provideadvancedsafetyforstudentsandstaffmembersofeducationalbuildings.
FoxMeadowMiddleSchool










Commercial/Warehouse/Manufacturing
Precast wall panel systems offer high value and long life while meeting demanding
requirements.Itprovidesasmooth,hardinteriorsurfacethatresistsabrasivedamage
causedbyheavyequipment.Also,precastallowsforgreatexpansesundertheroof
without perimeter support
columns, as well as openings
wider than conventional ones.
This makes it particularly
convenient for loading and
unloading materials and
supplies.  Floors can be poured
after the walls are erected and
the roof is in place. This
protects the floor from GCCOffice,Shop&Warehouse
constructiondamageandavoidsscheduledelaysduetoinclementweather.

Office TheAerospaceCorporation
Corporate owners and managers profit from the
accelerated occupancy, insurance and tax benefits,
andreducedconstructionfinancingthataprecastwall
panel system offers. The panels are an excellent
optionforanofficeparkenvironmentasexteriorscan
be matched to those of other buildings to help new
construction blend with existing structures. This
system also accommodates the moving of walls for
thepossibilityoffuturebuildingexpansions.




6
Religious
Withaprecastwallsystem,amultitudeofaestheticchoices,suchascustomizeddesignsandfinishes,areavailableto
create nearly any motif.  Also, insulated panels provide excellent sound reduction, events held in one space do not
disturbconcurrentactivitiesinadjacentspaces.Inaddition,precastwallpanelsofferlongtermenergyandcostsaving
benefitswithanearlymaintenancefreefaçade.
EasternHillsCommunityChurch

SecureEnvironments:FoodIndustry,Medical/LaboratoryFacilities
Precast wall systems offer clean, germfree environments for facilities, such as foodprocessing plants and medical
offices,wherethisisofutmostimportance.Thisisaneconomicalandeffectivewaytomeetgovernmentstandards.
Interiorpanelsurfacescanbegivenasmoothfinishthatiseasytoclean,freeofairvoids,andresistssoiling.Inaddition,
theconcretecanbemicrobioticallytreatedtoprovideenhancedmildewresistance.Also,ledgesthatmightcollectdirt
canbeeliminated,anddurableinteriorwallsareabletoendurethecontinuedapplicationofharshchemicals.

JudicialandMilitary
Precastwallpanelsarestrongandhardwearingforanincreasedlevelofsafetyandsecurity.Theyresistrust,dents,and
punctures as well as forces of nature that can damage or destroy other buildings. Panels can be produced to exact
specifications in a wide variety of dimensional choices tomeet buildingrequirements. Precast insulated panels have
beentestedandshowntoexhibitexceptionalblastresistance,atypicalrequirementforthesefacilities.
FortCarsonDivisionHeadquarters

7
ProductVariations
Wallpanelsareversatilepiecesthatcanbeusedasarchitectural,structural,orcombinationelements.Insulatedwall
panelscanbedesignedascompositeornoncomposite,andloadbearingornonloadbearing.Inaddition,panelscanbe
castwithblockoutsforelectricalconduit,HVACductwork,windows,andentranceandegressopenings.Becauseofthe
substantialnumberofvariationsandcombinationsofpanelconfigurationsandmanufacturingtolerances,thismanual
hasprovidedyouwiththefollowinglistoffeaturesthatcanhelpwithproductselectionandspecification.

ManufacturingTolerances
There are two distinct sets of tolerances in the manufacturing of precast/prestressed concrete.  These can include
dimensional,surfacefinish,andcolorvariation.TypicalstructuralgradeproductisproducedunderPCIMNL116while
architecturalproductisproducedunderPCIMNL117.ThishowevershouldnotimplythatallproductmadetoPCIMNL
116 is gray and has large variations in dimensions or all exterior façades of structures are produced to the more
stringentarchitecturalrequirementsofPCIMNL117.Anycombinationofthequalityguidelinescanbeputtogetherto
facilitatethemosteconomicalwallpanelsystemwhileensuringtheaestheticandarchitecturalintent.Asopposedtoa
paintedprecastpanel,abrickpanelwouldrequiresignificantlytightertolerances.

OurStructuralPluspanelsaremanufacturedtoPCIMNL116fordimensionaltolerancesandPCIMNL116forcolorand
surfacefinishvariation.

Color
Panelcolorisdevelopedthroughavarietyoftechniques:
x ColoredPigment
x ColoredAggregate
x SurfaceFinishVariation
x SupplementalMaterial–PaintandStain

StructuralPluspanelscomeincolorsbasedonlocalaggregates,graycement,andpigment.Currently,thesecolorsare
Gray,CinnamonToast,andCream.

Finish
Panelfinishescanvaryfromaformfinish,toaverysmoothfinish,toaheavyexposed
aggregate finish.  The installation of the finish is a cement or matrix removal process.
Thematerialremovalcanbeaccomplishedwithahighpressuresand,oracidandhigh
pressurewash.



ThermalEfficiency
These panels can be insulated with limited solid
zones to 100 percent thermal efficient.  Typical
steadystatethermalRvaluesareontheorderof
8to15.Ifthermalmassisaccountedfor,andthe
interiorsurfaceistheconcretepanelorcontains
a single layer of gypsum, effective Rvalues can
be on the order of 12 to 22.   In addition to R
values, precast concrete provides the advantage
of thermal mass.  This benefit enables the
storage of heat which is released over time,
leveling the peak fluctuations in mechanical
HVACequipmentdemand.

8
Loadbearingvs.NonLoadbearing(Gravity)
Forthemostefficientstructuralsystem,theexteriorwallpanelsshouldbeloadbearing.Thissolutionpreventsinterior
columns adjacent tothepanels, and eliminates the roofor floor perimeter spandrelbeams.  Nonloadbearingpanels
canbereferredtoascladding,orcurtainwallsystems,andarecommonbuildingenvelopes.Theycanbeconnectedto
any type of structural frame, including precast concrete, castinplace concrete, or steel. When designated as non
loadbearing, they are typically designed to resist wind and seismic forces generated by their own weight.   Either of
thesebearingsystemscanincludewallpanelswithorwithoutwindows,spandrels,mullions,orcolumncovers.


TypicalCombinations
IndustrialGradeWall
FoxMiddleSchool ConcreteColor Gray
SurfaceFinish PaintReady
Insulation Insulatedornoninsulated
Loadbearing Loadbearingornonloadbearing
InlayMaterial None
Liner None
DimensionalTolerance PCIMNL116
ColorandSurfaceFinishTolerance PCIMNL116
SandCreekHighSchool


StructuralPlus

ConcreteColor Gray,Cream,Cinnamon
SurfaceFinish Lighttomediumsandblastfinish
Insulation Insulatedornoninsulated
Loadbearing Loadbearingornonloadbearing
InlayMaterial Thinbrick,block
Liner Thinplasticliner
DimensionalTolerance PCIMNL116
ColorandSurfaceFinishTolerance PCIMNL116
FalconHighSchool


HighEndArchitectural

ConcreteColor Anyvarietybasedonaggregateandpigment
SurfaceFinish ExposedAggregate,sandblast,oracidetch
Insulation Insulatedornoninsulated
InlayMaterial Stone,brick,etc.
Liner Stone,brick,etc.
Loadbearing Loadbearingornonloadbearing
DimensionalTolerance PCIMNL117
ColorandSurfaceFinishTolerance PCIMNL117

CentraliaHighSchool

9
ProductTypes
ShearWalls
Shear walls are also structural components and function as part of the lateral resistance system of a building,
withstanding forces from wind, blast, or earthquake. They can be load bearing or nonload bearing and include both
solidandwindowpanels.

Structural panels can be loadbearing or nonloadbearing, but are manufactured to PCI MNL 116 tolerances.
Loadbearing panels are structural components that transfer gravitational or vertical loads from other elements, and
contribute to the strengthand stability of a structure. Loadbearing elements include solid wall panels andcomposite
andnoncompositeinsulatedpanels,bothofwhichcancontainblockouts.

ColumnCover
Acolumncoverisaprecastpanelthatcoversoneormoresidesofacolumn.

Spandrels
Spandrelsareusedtofillthespacebetweenthetopofawindowordoorinonestory,andthesillofthewindowinthe
storyabove,oraparapet.Aspartoftheexteriorofabuilding,spandrelpanelsspanthedistancebetweenwallpanels
thatactascolumns.Thesepanelscanbeloadbearingornonloadbearing.

Mullions
Mullions are structural components that vertically divide adjacent windows and/or doors. They are nonstructural
membersanddonottypicallycarryanydeadload.Theywillgenerallyonlysupportwindloadfromthewindow/door
unit,carryingitbacktothebuildingstructure.

TrussWall
EnConalsoprovidesametaltrusswall.Thisisamediumperformanceproductthatcan
have an enhanced thermal efficiency over solid panel and panels with solid zones in
through the insulation.  Prestress steel serves as primary outofplane flexural
reinforcing.  A metal truss is used for reinforcing to produce composite shear transfer.
Thepanelsaredesignedasnearly100%compositeandthusrequirelessconcretethana
noncompositepanel.

TrussWallAdvantages
x Compositeactionbetweenwythes
x Lighterpanel
x EdgetoedgeInsulation
x Minimalthermalbridging
x Minimalcondensationregions
x Increaseduseablefloorarea











10
CarbonCast®
EnCon also provides CarbonCast®.  This is a high performance product that can be
thermallyefficientwithcarbonfiberreinforcement.Prestresssteelservesasprimaryout
ofplaneflexuralreinforcing.Aresinbonded,carbonfibergridisusedforreinforcingto
produce composite shear transfer. Since carbon is noncorrosive and nonthermally
conductive, it eliminates the risk of internal deterioration and thermal loss.   Since the
panels are designed as 100% Composite, the panel requires less concrete, allowing the
panels to be thinner and lighter weight. In addition, carbon can be used in the panel as
transversereinforcement,limitingtheexposureandriskofcorrosion.

CarbonCast®Advantages
x Compositeactionbetweenwythes
x Thinnerpanel
x Lighterpanel
x EdgetoedgeInsulation
x Minimaltonothermalbridging
x MinimaltonoCondensationregions
x Thermallynonconductivewytheconnections
x Increaseduseablefloorarea


BuildingSystemVariations
EnvelopeSystems
Architecturalornonloadbearingpanels,oftenreferredtoascladdingorcurtainwalls,are
the most common use of precast for building envelopes. They can be connected to any
type of structural frame, including precast concrete, castinplace concrete, or steel.
Architectural wall panels enclose a space and do not transfer vertical loads. They are
typicallydesignedtoresistwindandseismicforcesgeneratedbytheirownweight.These
precastpiecescanincludewallpanelswithorwithoutwindows,spandrels,mullions,and
columncovers.

CECProject
LoadbearingSystems
Loadbearingpanelsarestructuralcomponentsthattransfergravitational
orverticalloadsfromotherelementsandcontributetothestrengthand
stability of a structure. Loadbearing elements include solid wall panels
andcomposite and noncomposite insulated panels,both of whichcan
containblockouts.










11
LateralForceResistingSystems,eitherLoadbearingorNonLoadbearing
Shearwallsarealsostructuralcomponentsandfunctionaspartof
thelateralresistancesystemofabuilding,withstandingforcesfrom
wind, blast, or earthquake. They can be loadbearing or non
loadbearingandincludebothsolidandwindowpanels.





UniversityofColoradoatColoradoSpringsDorms

ArchitecturalEnhancementPanels FolsomFieldAddition
Architecturalwallpanelscanbeusedtoenhancethe
appearance of multiple construction applications.
Integrated with steel, stone, masonry, or even cast
inplaceconcrete, highly detailed and ornate panels
candramaticallyimprovetheexteriorofastructure.
Personalized emblems, symbols, or logos add
additionalvisualinterest.

ProductSystemBenefits
Precastconcretewallpanelsystemshavedemonstratedhighvalueandversatilityineverymarket.Noothermaterialor
systemcombinesasmanybenefitsasaprecastwallsystem.

AdvantagesofanEnConPrecastWallPanelSystem
TheEnConCompanieshavedeliveredhighqualityprecastconcretestructuresthroughouttheUnitedStates,andholda
strong commitment to partnership, customer care, and product excellence.  From design support to product
installation,theymaintainafullservice,integratedapproachtodelivery.Asaresult,clientsreceivethebenefitsand
convenienceofasinglesourcesupplier.Thishelpslimittheprojectrisk,aswellasthenumberofsubcontractsneeded.

x DesignFlexibility
Precastwallpanelscanbeproducedindifferentsizesanddepths,offeringmoredesignflexibilitythanother
building systems where components may be limited to standard sizes and dimensions. Wall systems can
accommodate nearly any design requirement, unusual lengths and widths, wide openings, and varying wall
thicknesses.Speciallyconstructedformsallowforthecastingofcurvedorradiusedpanelstocreateuniquely
shapedbuildings.Panelscanbecastwithblockoutsforwindows,ductwork,andelectrical,aswellasentrance
andegressopenings.Panelscanalsobefabricatedwithpreinstalledwindowsandstudnailersappliedatthe
plant.Theentirepanelcanthenbeliftedintoplacewithminimumpreparation.

x AestheticallyVersatileExteriors
Precast is an extremely adaptable material and offers unlimited aesthetic options. Exterior surfaces can be
finishedtocomplementthesurroundinglandscapeaswellasmatchthedesignofanexistingstructure.Precast
easilyaccommodatestheuseofotherbuildingmaterialstocreateacohesiveappearance.Uniqueandintricate
personalizeddesignscanbecastintothepanelsusingformliners.Thismakesiteasytoadddetailssuchas
revealpatterns,names,emblems,andsymbols.Multicolorpainttreatmentscanfurtherhighlightarchitectural

12
 features.Panelscanbeproducedinoneormultiplecolors,andalsoinavarietyoftexturesandaggregates.A
varietyofsurfacingtechniquesmayalsobeappliedtothepanels.Theseincludesandblast,acidetch,trowel,
polishing,stain,andpaint.Theresultscanincludeasmooth,ribbed,orexposedaggregatefinish.Theycanalso
replicate the appearance of wooden boards.  Furthermore, panels can also be clad in brick, tile, terra cotta,
limestone,sandstone,granite,marble,orstone.

x InteriorSurfaces
Panelscreateadoublewallsystemwheretheinteriorwallsareessentiallyprefinished,eliminatingtheneedfor
andexpenseofadditionalsurfacetreatments,includingdrywall.Awidevarietyoffinishes,includingpaint,can
beappliedtothepanelsifdesired.Intermediatebracingisnotneeded,aspanelstypicallyofferclearheightsof
30ftcreatingunobstructeduseofthefullinteriorheightofthebuilding.

x Economical
EnCon’sprecastwallpanelsareanexcellentbudgetconsciouschoicethatdoesnotsacrificehighquality.Wall
panelsystemsarecostcompetitivewithothersystemsthatdonotofferthebenefitsofprecast.Fabricationon
a permanent long line facility allows for more panels to be cast simultaneously, resulting in decreased labor
costsandanacceleratedprojectschedule.Precastwallsystemsfacilitatebuildingexpansions,whichhelpkeep
futureconstructioncoststoaminimum.

x ExpeditedConstructionSchedule
Wallpanelsystemscanbecastatthemanufacturingfacilitysimultaneouslywithjobsitepreparationandthere
isnoneedtocasttheinteriorslabbeforepanelerection.Thus,installationcanbeginimmediatelyfollowing
delivery.Inaddition,theavailabilityoflargepanelsizesmeansfewerpanelstobecastanderected.EnCon’s
wallpanelsandsystemscanbefabricatedanderectedininclementweatherconditionsandinenvironments
thatwouldotherwiseinterferewithbuildingconstruction.Finishedinteriorwallsalsoeliminatethetimeand
expenseoffurringstripsanddrywall.

x GreenConstruction
Sustainable, thermally efficient, and having low life cycle costs, a precast wall system is an excellent building
solution in today’s environmentallyconscious climate. Plant fabrication results in reduced construction time and
lessjobsitewasteandcongestion,allofwhichhavelessofanimpactonthelandscape.Unlikeotherbuildingand
framingmaterials,precastconcretedoesnotreleasetoxinswhenburned.Concreteprovidesthermalmass,which
delaysheattransferthroughbuildingwallsandmoderatesindoortemperaturefluctuationsasoutdoortemperature
varies. Along with lowering heating and cooling costs, this helps to meet stricter energy requirements.  With
integral insulation,highperformance sandwich panels further reduce energy consumption, forgoing theneed for
extrainsulation.TypicalRvaluescanrangefrom8tomorethan18.

x HighQuality
Plant casting yields a more predictable product with greater quality control, consistency, and finish. With focus
placedonultimatestrengthratherthancuretimeandtemperature,precastwallpanelsarestrongerthanconcrete
blocksorwallsthatarecastonsiteandtiltedintoplace.Prestressingreinforcementyieldsinherentstructuraland
serviceabilityadvantages,suchasincreasedstrength,ductility,crackcontrol,andpanelflatness.

x SafetyandSecurity
Precastconcreteisnaturallyfireresistantwhilewallpanelsystemsinhibitfirespread.Thishelpstoensureablaze
remains contained.  Consequently, more time is provided for fire detection, evacuation, and suppression.  Wall
panels protect a building from the spread of adjacent fires and aid in compliance with special building code
requirements.Foamblockoutsareusedtoaccommodateplumbing,mechanical,andelectricalpenetrations.This
minimizes the amount of onsite core drilling and decreases jobsite risk. Precast concrete’s structural stability
providesresistancetodamagecausedbyforcesofnaturethatincludingseismicevents.Wallpanelscanbetreated
andfinishedtocreatearoomfreeofdust,particles,andothercontaminants.Thesecharacteristicsareofparticular
importancetohealthcareandresearchfacilities.






13
x MoistureResistanceandAcousticalControl
Fabricatedwithalowwatertocementratio,highlydenseprecastconcreteinhibitswaterpenetration.Precastwall
panelseliminatetheneedfordrywall,supplyinganaddedmeasureofprotectionagainstmoldandmildewgrowth.
Panels,especiallyinsulatedpanels,diminishnoisetransmissionforgreaterprivacyandreducesoundtransmission
fromoutsideabuildingtotheinside.

x LoadbearingvsNonLoadbearing
The wall panel system can function as a structural loadbearing element as well as an architectural skin. This
eliminates the need for floor and roof support framing. In many cases, spread footings are not necessary as a
specialbuiltinbeamfeatureatthebaseofapanelenablesittospanfromcaissontocaisson.

x FireResistance
FireratingsarebasedonaRationalFireDesigncalculationmethodoranIBCPrescriptiveFireRatingmethod.Afire
ratingisdependentuponequivalentthickness,heattransmissionthickness,coverontheprestressingstrand,and
endrestraint.Astandard8in.thickHollowCoresystemhasatwohourfirerating.However,higherratings(three
or four hour) may be achieved with topping and gypsum board, or the application or a sprayon, fireresistant
materialtotheundersideoftheslab.

x BlastResistance
Insulatedwallpanelshavebeenshowntoholdsuperiorstrengthsandenergyabsorptioncharacteristics.Thishas
been revealed through recent, full scale testing and blast simulations with end results that place precast wall
systemshighabovetraditionalbuildingmethods.





















14
Precastvs.EIFS
EnCon’sprecastproductsstanduptootheroptionswithintheindustryasthepremierbuildingsystem.

ThequalityofEnCon’sInsulatedPrecastConcreteProductsisunsurpassedaseachpieceisengineeredagainstcracking
underallserviceconditions.Theirproductsarepredominantlyusedfortheexteriorbuildingenvelopeandaredesigned
to prevent moisture infiltration into the structure, for the life of the
structure.Inaddition,manyoftheproductsareprestressed,areinforcing
technique developed to increase span, capacity, and decrease the
propensity for cracking.  Because of the high standards placed on the
precastdesignandmanufacturingprocess,itisamoredurableandefficient
choicethanitscounterpartswithintheindustry.

InsulatedConcreteWallPanel




EIFS, an alternative to precast, is a finishing technique in which crementitious top and base coats are applied to
ExpandedPolystyreneInsulation.Theinsulationisthenapplieddirectlytothestructuredsheetingeitherthroughglue
or mechanical fasteners.  Due to this method of construction, the finished exterior can be somewhat soft and
susceptibletocracking,indentations,andpenetrations,damagingthefinishedsurface.Inturn,waterinfiltrationand
moldbecomecommonproblems.

AnotherformofEIFSconsistsofapremanufacturedpanelofinsulationwithastructuralmetalframecoatedinathin
baseandfinishcoat.Althoughthisisasimilarconcepttothatofaprecastpanel,theEIFSPanelsystemistypicallynot
engineered for rigidity or to prevent surface cracks.  The latest EIFS system designs have included a vapor barrier
between the insulation and
sheathing.Althoughthisprovides
better moisture control in the
field, portions of the insulation
and mechanical fasteners still
penetrate this membrane and
create a potential source of
moistureintrusion.





 TypicalEIFSCrossSection



15
TypicalDesignandDeliveryProcess
The flow chart below highlights the general process from project initiation to completion. The tables contain
representative project schedules and demonstrate the primary scheduling benefit of precast concrete construction.
Thereareanumberofinterrelatedyetoverlappingactivitiesthatallowfasterturnaroundandquickerjobcompletion.

Project Preliminary
Identification Design
Assistance

Estimate and
Award Project

Calculations,
Final Design Erection Drawings,
and Details

Submittal
and Approval
Process

Manufacture, Store, Final Erection

and Transport and Production
Drawings

Erection and
Field Finish

Project
Completion

16
EmbeddedBrick
Whenthinbrickiscastintoconcretewallpanels,thisproducesembeddedbrick;amaterialthatcanbeimplementedto
createanentirestructureaswellasdecorativeelementsonabuildingfaçade.


RoseMedicalCenter

AdvantagesofEmbeddedBrickoverTraditionalMasonry
Along with aesthetic appeal and low cost, there are numerous benefits surrounding brickembedded concrete over
conventionalmasonry.Theseincludenolintels,flashing,weepcavities,airspace,waterproofing,orefflorescence.In
addition,thereisnotimeconsuming,onsiteconstructionofmasonryproducts.

OtherBenefitsInclude:
x Pleasingtraditionalappearanceofbrick,whileleveraging
thestrength,speed,andeconomyofprecastconcrete
x Duetolowabsorptionrates,thinbrickisratednotto
effloresce
x Inlaidthinbrickwallsrequirednoperiodicsealingortuck
pointingrepair
x ThinbrickprecastconformstoPCIstandardsforbrick
embeddedinprecast


SplitfaceInlay



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Forthoseseekingabrickfinishthatisbothvisuallyappealingandeconomical,EnConoffersthinbrickwallpanelsthat
comewithvariousoptionsincludingarangeoffinishes,sizes,andshapesofbrick.Therearealsopiecesthatareusedto
createarchitecturalcorners,arches,soldiercourses,andothertraditionalbrickpatterns.

BrickPatterns

RunningBond FlemishBond SoldierCourse StackBond EnglishBond

Arches NumerousBondingPatterns OrnateCorbels


BrickSizes

ModularBrick

NormanBrick





UtilityBrick




BrickCorner

 EdgeCap



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RequirementsofEmbeddedBrickUnits
x Havedimensionaltolerances+0in.1/16in.onallunits8in.orunder;+0in.3/32in.onallunitslargerthan8
in.
x Havea24hourcoldwaterabsorptionratenormorethan6%whentestedperASTMC67
x Maintainaconsistentplaneof+0in.1/16in.(+01.6mm)
– AllShapesshallconfirmtothearchitect’sspecifiedanglewithatoleranceof±1(MeasuredperASTM
C67)
x Maintainanoutofsquaredimension±1/16in.(±1.6mm).MeasureperASTMC67
x Rate“noteffloresced”perASTMC67
x Exhibitminimumtensilebondstrengthor150psi(1.0MPA)whentestedperASTMC482
x Exhibitnodetectabledeterioration(spalling,cracking,chafing,etc.)whentestedinaccordancewithASTM
C666MethodB,modifiedtowithstand300cycles
x Beshowntodemonstrateminimumofmodulesofruptureor250psiper(1.7MPA)whentestedinaccordance
toASTMC67
x Rate“notaffected”bychemicalattackwhentestedperASTMC650

ConsiderationswhenChoosingEmbeddedBrickWallPanels
Anumberofthingsshouldbeconsideredduringthedesignanddetailingofeachspecificproject.Theseincludebrick
andpanelsizesandshapes,loadbearingconditions,panelopenings,andbrickpaneltolerances.

x Modularbricksizesshouldbeusedwhendeterminingpanelwidths,heights,andopenings.
x Theuseofconcretebandingattheedgesofprecastpanelsandopeningsshouldbeconsidered.Bandingcan
minimizethecostofhavingtocutbricktooddsizes,ortheneedtobuildpanelstosizesthatonlyfitthe
moduleofthebrick.Bandinghelpswiththisbycreatingasolidconcretefacealongapaneledgetowhichthe
brickissetagainst.Itcanalsobeusedtodifferentiatefloorlocations,paneljoints,andotherarchitectural
effects.Bandingalsopermitspanelheights,widths,andopeningsizestobenearlyanydimension,
independentofbrickcoursing.
x Itisvitalthatmasonrycoursingbecontinuousfrompaneltopanel,bothverticallyandhorizontally.Thisis
importantwhenconcretebandingisnotusedattheedgeofpanels.
x Whenaformlinerpatternthatisrectilinearormodularisused,aligningthebrickpatternwiththeconcrete
patternshouldbeconsidered.Thiswillhelptoalignopeningsinthedifferentpatterns,aswellascreateawell
ordered,visuallypleasingfaçade.
x Whenusingconcretebandingatjambsofwindowordooropenings,¾in.istheminimumrecommended
concretejambbandwidth.
x Precastheaderandsillheightsandlengthsshouldbeplacedsymmetricallywithinthebrickmodularpattern.
x Cornerbrickcanbeusedforbothpanelendsandbrickreturnsatwindowanddoorheadsandjambs.Opening
sizesshouldfitsymmetricallywithinthebrickmodule.Pleasenotethatcreatingopeningsizestofitthebrick
modulemayrequireorderingcustomsizewindows.
x Althoughitismorecostlythanusingstandardmodularsizes,cuttingbricktospecialsizesatedgesofpanels
andpanelopeningscanbeachievedifnecessary.Ifaspecialsizeopeningisrequired,theopeningshouldbe
locatedsothatthebrickiscutequallyoneithersideoftheopening.
x Industrystandardmanufacturingtolerancesofbothprecastpanelsshouldbeconsideredduringthedesignof
eachproject.
x Tolerancesthatshouldbetakenintoconsiderationincludefloortofloorheights,panelheights,brickcoursing,
jointsizes,loadbearingconditions,andjointdetails.




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FrequentlyAskedQuestions
The following section relates to typical questions regarding wall panels, specific terms and properties, and the
manufacturinganderectionprocess.

WhatisaSandwichPanel?
Insulated wall panels are also referred to as sandwich panels. An inner core of
insulation is surrounded or sandwiched between two precast concrete layers or
wythes.

WhatisaWythe?
Awytheisalayerwithin,oronthesurfaceofasandwichpanelorinsulatedwall
Panel.

WhatisaWytheTie?
A Wythe Tie is the name of the material that connects two or more layers of
concrete(wythes)togetherinaninsulatedwallpanel.



WhatareRvalues?
Rvalue, or Thermal Resistance, is one measurement of FactorsthatImpacttheThermal
the thermal performance of a system.  There are two PerformanceofaStructure
typesofRvaluesdiscussedintheconstructionindustry. Effectsof
Daily Analysis
These are Steady State Rvalues and Effective Rvalues. Temperature Duration SteadyState
RValue
The Steady State Rvalue is traditionally based on the Thermal Range
measured, one dimensional resistances of the Shorts

construction materials that comprise the system for a Humidity

Geographic
givenassemblyofmaterials. Position
AirInfiltration

FloorSystem
AlthoughthereareanumberoffactorsthatinfluenceR
Foundation
values, the Effective Rvalue is primarily a combination Conectivity ThermalMass
ofSteadyStateRvalueandThermalMass.

There are no standard methods of calculating Effective Rvalues.  One method, however, is the development of a
multiplierformasswallsystemsortheDynamicBenefitforMassiveSystems(DBMS).ThismultiplierrelatestheSteady
State Rvalues to Effective Rvalues using a standardized lightweight wood frame structure as a base line.  The
standardizedhomeismodeledwitheachwallsysteminordertodeterminethetotalbuildingenergyloadforagiven
durationandclimate.

The Steady State Rvalue of the exterior wall system for the standardized lightweight wood framed home is then
manipulateduntiltheenergyloadsarethesameasthemasswallsysteminquestion.TheratiooftheSteadyStateR
valueofthemodifiedwoodstructuretotheSteadyStateRvalueofthemasswallsystemisequaltotheDBMS.One
benefitofthisapproachisthatitallowsfortheevaluationofsimilarmasswallconstructiontechniques,wallassemblies
ofsandwichedinsulation,andwallassembliesofsandwichedconcrete.

TheindustrystandardforthermalperformancecomparisonshouldbeacomparisonofSteadyStateRvalues.
ThismethodisanexcellentpredictorofRvalueswithvariationsinmaterialthickness,solidzones,orthermalshorts.It
has been adopted by the Precast and Prestressed Concrete Institute Design Handbook as the preferred method of
calculatingRvaluesforcomplexassemblies.



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