Precast and Infrastructure

The United States' intricate network of vital infrastructure sectors aims to ensure that our country runs smoothly and its residents are safe. The assets, systems, and networks are governed by Presidential Policy Directive 21 (PPD-21) and protect the national public health and safety and the national economic security. Significant national resources are devoted to advancing and improving these sectors on an ongoing basis.

What is Classified as Key Infrastructure?

PPD-21 encompasses 16 key infrastructure sectors that have been identified. These industries are so vital that the destruction or incapacitating of even a small portion of them would have a crippling impact on overall national security. Here are the sixteen sectors:

• The chemical industry is in charge of turning raw materials into more than 70,000 goods that are necessary for survival.

• The commercial facilities sector is in charge of many locations that gather big crowds of people, including office buildings, malls, and accommodations.

• The communications sector is in charge of delivering interconnected services like wireless and satellite, as well as the providers who collaborate to guarantee interoperability.

• The critical manufacturing sector is responsible for the components vital to economic growth and national security.

• The dam sector is in charge of hydroelectric power generation, flood control, industrial waste management, and many other vital water retention and control services.

• To meet the needs of the US military, the Defense Industrial Base Sector is in charge of the research, development, production, delivery, and maintenance of military weapons systems, subsystems, and components.

• The emergency services sector is responsible for the highly skilled individuals who respond to incidents nationwide.

• The energy sector is accountable for performing an "enabling role" to provide a reliable energy supply to all other vital infrastructure.

• The financial services sector is in charge of hundreds of depositories, investment product suppliers, and companies that provide credit and financing.

• The manufacturing, processing, and storage of food supplies are done primarily by privately owned businesses in the food and agricultural sector.

• The government facilities sector is in charge of various structures that the federal government either owns or leases for public and private functions.

• The healthcare and public health sectors safeguard the economy against terrorism, pandemics, and natural disasters.

• The information technology sector ensures the security of technologically related systems and services used by enterprises, governments, academic institutions, and citizens.

• The nuclear reactors, materials & waste sector oversees 20,000 licensed users of radioactive sources, research/test reactors, fuel cycle facilities, and operating and retired reactors.

• The Transportation Systems Sector ensures that goods and people are transported safely, quickly, and securely across the country's transportation networks.

• The Water & Wastewater Systems Sector provides clean drinking water and treats sewage for the entire country.

Why Highway and Bridge Infrastructure Works with Precast

Due to the country's vast number of bridges, roads, and highways, many of which will need to be updated or repaired, roads and bridges will continue to be the primary use for precast concrete in infrastructure construction.

Our country's infrastructure has traditionally relied heavily on precast concrete. DOTs have utilized it for various purposes, including walls, bridges, barriers, and more, due to its robustness, dependability, quality, and ease of installation.

Other precast parts stand out because of inherent colors, unusual shapes, insets, and finishes that give them a second role. Some precast elements do their purpose diligently but go mostly unnoticed as they blend into roadside environments.

These elements provide much more than solid infrastructure. Highway sound walls have embedded regional animals or distinctive patterns, giving them life. Other states have made architectural choices like natural stone, wood grain, or brick that complement the neighborhood's aesthetics. Precast is ready to take on the challenge of being not only a superior structural construction material but also an aesthetically versatile one.

Precast concrete offers the appropriate appearance, quick installation, and long service life. Precast concrete may frequently be installed more quickly than competing materials. Retaining walls and MSE in a variety of forms are also offered by precast manufacturers around the nation.

Despite their higher cost, precast concrete components will increasingly be used in new and repair road and bridge construction. For instance: 

• Because of their lightweight and capacity to endure stresses brought on by the weight of other bridge components and strong traffic loads, prestressed bridge components, tees, and slabs are utilized on bridges.

• Because they are strong and have extended lifespans, precast concrete sound and traffic barriers are frequently employed.

Precast concrete may span anything from gullies to gorges and can reflect the architectural character of a community while also protecting the environment. Precast can offer an aesthetically pleasing, long-lasting design, whether the product is a short-span bridge or a full solution that can cross a significant river.

Benefits of Precast for Infrastructure Projects

The US has an open society, making it susceptible to events that endanger safety and security. Aside from unpredictable and uncontrollable natural disasters like floods, tornadoes, earthquakes, and hurricanes, the US also faces several covert adversaries who aim to harm our way of life through physical attacks on buildings and transportation systems and cyberattacks on the financial and technology sectors. Precast concrete building products address a demand in the ongoing endeavor to safeguard these national treasures.

Blast Resistance

Precast concrete is incredibly resilient to the concussive effects of blasts and can be built to withstand gradual collapse. Precast is a great option for data centers, military and governmental buildings, and other locations holding critical equipment and information because of this property.

Fire resistance

Precast concrete buildings do not burn and contain fires, giving first responders a chance to evacuate residents and stop the spread of the fire. Concrete is fireproof, which helps to control fires and reduces total damage to the structure in the event of a fire.

Storm resistance

Precast concrete's intrinsic strength is unaffected by strong winds, rising water, or vibrating ground. Precast concrete "weathers the storm" better than any other building material and is used in FEMA-approved projects due to its durability.

Sustainability

Precast concrete has replaced other building materials as one that supports the "one and done" attitude as we have come to appreciate the necessity to construct durable structures with ecologically friendly features. Precast construction will last for decades, as opposed to other building materials that need continual maintenance and replacement.

Reduced maintenance

Because precast concrete is stronger and more durable than conventional building materials, it needs less "service after the sale." Both interior and exterior precast applications are top performers in all climates and geographical regions due to their exceptional mold/mildew resistance and great longevity.

Resource-Efficient

90% of concrete's composition comprises its primary element, water, coupled with sand, stone, or gravel. Surprisingly, each ingredient's sourcing and assembly use very little energy. Cement, which makes up 10% of concrete, is also the component that releases all of the CO2 into the atmosphere.

Makes for Energy-Efficient Buildings

Concrete makes it possible to restore our infrastructure efficiently, thanks to LEED certification for construction. Insulation and little air infiltration are frequently incorporated into concrete construction techniques to increase energy efficiency.

Additionally, recycled materials can be used in concrete, reducing both the carbon footprint and the number of materials that would otherwise wind up in a landfill. Industry preferences for more environmentally friendly concrete are fly ash and slag.

Has a Long Service Life and Quick Build Time

Concrete is incredibly resilient to the elements and long-lasting, making it the ideal material for rebuilding our infrastructure. Additionally, new and improved concretes are lighter and stronger than traditional precast. Compared to other building materials like steel, wood, and asphalt, concrete is also the undisputed champ in terms of sustainability and cost-effectiveness.

The selected concrete reinforcement, however, requires more consideration. Choosing the appropriate rebar can make all the difference in corrosion. Concrete structures that use stainless-clad steel reinforcing bars have demonstrated lifespans of more than 100 years.

Precast concrete projects can be constructed quickly in emergencies, and precast concrete factories have completely changed the game for places that need to be extensively rebuilt quickly.

Precast Bridges

For bridges, as well as other commercial projects, precast and prestressed precast concrete have earned a place of distinction as a preferred building material. The reliability, affordability, and low maintenance alone add immeasurable value to this product.

History of Precast Bridges in the United States

Photo via Structurae (Walnut Lane Bridge (1950), Philadelphia, Pennsylvania (HAER, PA,51-PHILA,715-5))

The major precast bridge breakthrough occurred in the 1950’s and 1960’s as a result of the massive increase in road traffic and the construction of new interstates. Fast and affordable solutions were required to prevent the disruption of the moving traffic. The creation of bigger and more slender precast units was significantly aided by the entrance of long-line prestressing techniques into precasting factories which proved to be particularly useful for long spans and heavy weights for bridges.

First Prestressed Bridge

The Walnut Lane Bridge in Philadelphia, completed in late 1950, is regarded as the nation's first significant prestressed concrete bridge. The bridge was created by Belgian engineer Gustave Magnel and his pupil Charles Zollman. The post-tensioned concrete beams were all cast in a single piece at the bridge site. A cable was run end to end through a planned aperture after the concrete had dried and set. The cable was given tension by a jacking device, which anchored it in place. In 1989–1990, the initial beams and superstructure were changed.

Although pretensioned precast bridge beams were manufactured before 1948, that year saw the debut of the first producers who began advertising and creating precast bridge beam ranges. Tennessee is where the first precast bridge in the USA was built.

How Precast Bridges Are Built

All types of bridges use precast to build both the superstructure and the substructure including vehicular, pedestrian, railroad, pipeline, and dock bridges. Flat slabs, neighboring box beams, pretensioned beams, as well as spliced and curved girders are examples of superstructures. Precast end bents, piles, and pile bent caps, along with precast columns, are examples of substructures.

What is a prestressed concrete bridge?

Prestressing is a method of applying stresses of a preset magnitude through tendons (often steel cables) to generate compressive stress to increase tensile strength. Prestressing is frequently used in bridge components, as well as other precast products.

Pretensioning involves pouring concrete over already-tensioned wires and letting it set up to solidify and secure the cables in place. The ends of the tensioned cables are cut and the tension is transferred into the beam or slab once the concrete has hardened and cured.

Pretensioning, which is more difficult than post-tensioning, is the current standard method for creating prestressed bridge beams. In order to retain the steel cables, referred to as "strands," in a highly tensioned state while the concrete is being poured around them in molds, pretensioning calls for the creation of sizable "casting beds."

Concrete is post-tensioned, which involves adding compression after curing. The tendons are tensioned and wedged to maintain the tension before being supplied through ducts cast into the finished concrete product. The aperture is then grouted after this.

What type of concrete is commonly used for bridges?

Concrete beams, spandrels, columns, single and double tees, wall panels, segmental bridge units, bulb-tee girders, I-beam girders, flat slabs, and hollow-core slabs are typical examples of structures that use precast concrete.

Precast Bridge Components

Precast concrete is a superior option for bridges and other traffic related construction such as noise barriers, median barriers, and pavement systems due to its structural and aesthetic versatility, resilience, speed of construction, high level of quality and durability. 

Precast Piles

Precast piles are one of the main components of precast bridges commonly used in areas such as Mississippi, Alabama, and Louisiana. Prefabricated, highly durable prestressed concrete columns known as piles serve as the foundation or support for buildings and bridges. Concrete piles are reliable workhorses and outlast wood or steel piles in maritime and coastal conditions.

Biloxi Bay Bridge

After the original bridge was destroyed by Hurricane Katrina, the new Biloxi Bay Bridge was designed using various precast components including precast piles that were designed not only to withstand a Category 5 hurricane but also vessel collision loads.

Precast Pavement

Precast pavement and precast bridge decks add an additional benefit and the greatest option for a high-volume, continuously used roadway. PCI-certified precast concrete replacement slabs are a lasting investment for transportation clients faced with deciding how best to spend limited infrastructure funds.

Lake Pontchartrain Causeway

The Lake Pontchartrain Causeway is a prime example of how precast can be used on a highly traveled roadway. The bridge is the main mode of travel over Lake Pontchartrain and sees over 40,000 vehicles every day. When safety became a liability, a total precast solution was chosen to bring the bridge up to modern-day design standards.

Precast NEXT Beams

Precast bridge designers are finding new ways to bring innovation to the industry. Through the creation of the NEXT Beam, the demand for a more effective bridge beam design entered the transportation world and is gradually transforming how bridges are maintained or replaced with an emphasis on cost-effectiveness, longevity, and design flexibility.

Cribbs Mill Creek Drainage Bridge

Contech, formerly known as Forterra, was involved with providing NEXT beams for the Cribbs Mill Creek Drainage bridge in Alabama. It was the first project in Alabama to use NEXT Tee Beams. The NEXT beams provided a clean line profile that did not require joint lines and removed possible future joint maintenance.

Advantages of Precast Concrete Bridges

There are numerous benefits to using precast concrete for bridges.  Not only is precast produced in a quality-controlled environment, PCI certified producers adhere to a strict quality control program to ensure their precast components are of the highest quality.  

Precast concrete bridge components also have uniformity because they are manufactured using the same molds and techniques.This means when they arrive at the job site, they are ready to be erected without additional work or forming.

As an offsite construction option, precast is manufactured in plants away from the job site.  This means they are shipped precisely when they are needed and do not require laydown space on tight job sites. The offsite manufacturing proves to be the perfect solution for environmentally sensitive areas on major highways or rural bridge locations.

Why is precast concrete cheaper?

When it comes to bridges precast concrete is a more durable and economical solution than other construction materials.  Precast concrete lasts longer, requires less future maintenance, and is produced in quality-controlled environments which ensures the quality of the components.  DOTs around the US look to precast to build their infrastructure so it lasts for decades with little upkeep.

How long does precast concrete last?

Precast concrete can be designed to perform for 100 years or more with minimal maintenance. This means that bridges designed with high-quality precast components such as those from PCI-certified producers continue to give value long after the initial cost of installation.

Accelerated Bridge Construction

Bridge repair and replacement procedures continue to improve thanks to close cooperation between the Transportation Research Board, the FHWA, the American Association of State Highway and Transportation Officials, and academic/industry partners along with the development of strategies such as accelerated bridge construction.

Key Takewaways 

Precast, prestressed concrete has taken its place as the material of choice for bridge building and other transportation-related projects. Precast continues to be a “go-to” option for government agencies and their engineers across the nation today. This development is the result of precast producer dedication to creating and developing cutting-edge products and technologies with the goal of improving the efficiency of bridges and other transportation-related structures.

Precast FEMA Storm Shelters

As extreme weather events become increasingly common, storm shelters are becoming more crucial across the US. In particular, hailstorms, tornadoes, and dramatic temperature swings have increased in the southern part of the US over the past few years. The upcoming decades are expected to have a similar perspective. Communities are looking into long-term, affordable options like precast concrete building to protect inhabitants.

A safe room is a fortified building created especially to meet FEMA requirements and offer nearly complete protection from extreme wind occurrences, such as tornadoes and hurricanes.

The occupants of a safe room constructed in accordance with FEMA guidelines will have a very high possibility of being protected from harm or death, according to our present understanding of tornadoes and hurricanes. This level of safety is referred to as "near-absolute protection."

Precast concrete satisfies every requirement for safe rooms in FEMA P-361. For storm shelters, it can be applied at the most fundamental design level. FEMA has stricter regulations than other building codes and mandates near-absolute protection for occupants during extreme weather events from wind and debris. The FEMA-selected wind speeds emphasize safety and call for the capacity to resist winds exceeding 250 mph. These exacting requirements are met by precast concrete.

Precast concrete gives value to a building in addition to protecting its residents. Precast provides structures a number of additional advantages, including:

• strengthened structural integrity

• protection from strong winds

• shorter construction periods

• advantages of thermal mass

Precast buildings sometimes function as multipurpose constructions and are built with gyms or auditoriums in mind. When individuals are compelled to utilize the shelter due to an extreme weather occurrence, these additional design features offer comfort and ease. The environment for inhabitants is improved by thick, insulated precast walls that absorb sound and FEMA-rated windows that let in natural light.

Advantages of Precast Storm Shelters

Structural Integrity

In order for a structure to be considered structurally sound, it must be stronger than the highest possible service stress or storm loading. A precast concrete safe room's structural integrity enables it to withstand service loads independently, without relying on surrounding support materials or soils. The building is deemed suitable to carry out its function if the planned strength of a precast concrete safe room exceeds the anticipated maximum applied stresses by an acceptable factor of safety and it complies with the extra FEMA 320 and FEMA 361 requirements.

Wind Protection

Tornadoes, hurricanes, and other such catastrophes rarely produce constant high winds. The pressure and stresses on the various components of a structure increase due to the constant varying and changing of wind speeds and directions. Wind forces operating on both sides (inside and outside) of a safe room structure will also have an impact.

Access and Entry

When choosing a secure room, access points are a crucial aspect to take into account. Easy accessibility, resistance to missile-type forces, and adequate attachment to a structural backing material are all characteristics that can be easily addressed in a precast concrete design for an access point (a door or window). Doors that comply with ICC-500, Section 306.3.1; windows that comply with ICC-500, Section 306.3.2; and all other openings that comply with ICC-500, Section 306.4 are valid entry and exit points for authorized precast concrete safe rooms that can survive tornado events.

Transportation and Installtion

Safe rooms made of precast concrete can be produced well in advance of installation on site. There is no need to wait for cast-in-place concrete buildings to set or cure because they are fully cured before being delivered to the site. Precast concrete safe rooms are readily available, competitively priced, and ready for use as soon as they are delivered. When compared to other materials, these precast advantages can save a project valuable days, weeks, or even months.

Thermal Mass

In the construction business, the term "thermal mass" refers to a material's natural capacity to absorb heat energy. The daily temperature changes in the building's internal spaces can be reduced by using a wall material with a high thermal mass. Because precast concrete has a high thermal mass, it requires a significant amount of heat energy to adjust its temperature. Because safe rooms are intended to house numerous people for an extended period of time, and because the ventilation and temperature within are crucial to ensuring occupant health and safety, the capacity of precast to moderate temperature changes is significant.

Ventilation

The 2006 IBC and IRC codes1 are applicable if the local jurisdiction has not issued a building code; ventilation in approved precast concrete safe rooms complies with the building codes or regulations adopted by the local jurisdiction. Precast concrete safe rooms have ventilation through either the ceiling or the floor. Any ventilation apertures must be shielded with a shield or cowl that passes missile impact testing. When specifying a precast concrete safe room, it is conveniently satisfied the requirement for mechanical ventilation if the safe room is intended for occupancy of more than 50 persons. During the precast manufacturing process, ventilation apertures are simply created and placed to precise requirements.

FAQs about Precast and FEMA Storm Shelters

What is the best material for a storm shelter?

One of the most typical materials found in shelters is concrete. It is quite heavy and loses some of its mobility in strong winds. There aren't many anchorages, extra fixtures, or installation needed. It is more affordable than other materials like steel, works well for many different storm shelter designs, and has a track record of withstanding severe weather.

How thick should a concrete storm shelter be?

According to FEMA, foundations must be at least 3.5 inches thick and in many cases winds will create loads that need greater thicknesses. More information and technical details from FEMA can be found here.

What types of materials are storm shelters made from?

Storm shelters can be made from a variety of materials including wood, steel, and concrete.  Some shelters make use of more than one of these materials that work together to provide protection to the occupants inside.

---

Robert J Curry Public Safety Center

The Robert J Curry Public Safety Center is built to FEMA 361 design and construction guidance for community shelters and can withstand the stringent 200 mph wind requirements. It is also used as a first responder shelter to house more than 275 personnel for pre and post-disaster functions.  The project consisted of 563 pieces of over 68,000 SF of exterior cladding most of which are 8” thick architectural precast concrete walls.

---

Precast Resiliency Resources

PCI recently highlighted precast and its ability to perform well in storms in their Ascent magazine.  Read some of the articles below.

Precast Enclosure Systems

Precast, as an enclosure system, provides a distinct advantage over other building materials.  Precast walls act as both the structural support for a structure and the component that provides the building’s insulation. By choosing precast, designers and clients are choosing a product that lasts a life-time and provides the support and protection needed to keep residents safe.

Types of Precast Walls

The versatility of precast walls ranges from providing architectural cladding for the exterior of a structure to a total precast system that provides insulation and structural support for the overall building. The following graphic depicts different types of precast walls.

Solid Walls

Solid walls are manufactured completely of concrete with insulation added to the interior finishing wall system. These types of walls can have any type of finish added to the back.

Sandwich Walls

Sandwich walls encompass the normal characteristics of a standard precast concrete wall with the added benefit of insulation which provides energy performance and moisture protection. More information about sandwich walls can be found in the State of the Art Sandwich Wall Panel technical document.

Thin-Shell and GFRC

Thin-shell wall panels are made from a thin outer-wythe of concrete and are connected to the backup structural system which usually consists of steel or concrete. Glass fiber-reinforced concrete (GFRC) is a type of thin-shell system which includes concrete that contains alkali-resistant glass fibers.

Lite Walls

Lite walls are used on precast structures and involve shear walls with a void that provides openness and a feeling of security. 

Depending on the needs of a client, one or more of these types of walls can be used to create the enclosure of the structure.

---

PCI’s Designer’s Notebook: Envelope Tolerances for Architectural Precast discusses the tolerances and clearances required for joining different building materials.

PCI also offers a collection of technical documents regarding Building Enclosure Design here for professionals looking for more guidance in designing building enclosures with precast.

---

Benefits

Like other precast components, precast walls provide valuable benefits for a building’s enclosure. Some of the benefits include: 

• Moisture Resistance: Precast wall systems are a barrier or face-sealed systems. They are superior to rainscreen systems because they do not require a space where water can collect and cause further issues. There are several supporting technical documents on the Building Enclosure Design web page under Air and Moisture Management.

• Thermal Mass: Precast concrete buildings save energy in various types of climates due to their ability to absorb and store heat and react very slowly to changes in outside temperature. This is further discussed in PCI’s Thermal Mass technical document.

• Quick Erection: Precast building enclosures can be erected in a few days or weeks which greatly reduces the overall project construction schedule.

• Eliminates Threats: The speed of installation eliminates the need for fireproofing, termite treatments, and additional insulation.

• Versatility: Precast walls can be designed to match a specific color or texture and help buildings blend into their surroundings in urban environments or match existing nearby structures.

When used as a building enclosure,  precast/prestressed concrete provides substantial benefits to both the owners and occupants of the structure. The versatility of concrete allows for designs of all sizes, shapes, and colors which meets the unique characteristics of each project. 

Precast and Carbon Emissions

At current rates, global carbon emissions are 36 billion tons annually and rising.  With a new focus on reducing carbon emissions to help counteract climate change, the precast industry has begun focusing on improving their processes and educating design professionals on the sustainability that concrete can bring in the long-term.

How much carbon does precast contribute to global emissions? 

Cement accounts for 3% of global emissions because of its use of clinker and limestone which emits carbon during production. This percentage also includes the actual energy inputs needed to produce the cement itself.

What is the comparison to timber?

Precast is often compared to timber when designers are considering sustainable materials to use in their structures.  Deforestation is responsible for 2.2% of global emissions (which is the difference between carbon from deforestation and the positive offset of replanting), with 8-10% of timber in the construction industry coming from deforestation.  Most timber comes from forest degradation which means trees are selected to be cut down leaving other trees intact.  

The actual carbon emissions of the timber industry is not fully analyzed because there are no international standards for tracking it.  Wood harvested from one country can be shipped to another with the carbon emissions impacted only being counted in one country or not counted at all. 

For example, each year 80,000 hectares of trees in North Carolina are cut down to produce wood pellets that are then burnt in power plants in the UK, as well as for paper and timber. The state does not count the resulting emissions. This makes it nearly impossible to determine the actual global emissions from the timber industry and compare it to precast.

Although it is true that if managed correctly for long-term carbon storage timber is an amazing carbon storage device, currently timber is harvested well before trees can fully store their potential for carbon making it less efficient in comparison to precast.

What ways can precast help with its emissions?

New technologies to capture or reduce carbon 

Since there are no other construction materials like concrete, professionals have been trying to implement new technologies to help reduce its carbon footprint.  There are a variety of methods being tested including direct-air capture (DAR) which is a machine that acts as an artificial tree collecting CO2 particles out of the air passed through it.  There are also ideas such as capturing CO2 from smokestacks and putting that carbon into cement products to replace certain high carbon materials in concrete like limestone with other less carbon producing compounds.

New greener concrete formulas

Concrete professionals are currently working on other types of cement to help counteract the carbon emissions of current products.  One of these newer innovations is called PLC or Portland-Limestone Cement.  This concrete provides the same durability and resilience, but has a reduced carbon footprint of 10%. It can be used for basically any structure with no modifications to mix design or placing procedures.

Reduces waste over the long term 

At its core, precast is inherently resistant to storms and provides protection from wind, surge, and flying debris.  This storm resistance has been confirmed through numerous impact tests.  But aside from its resistance, precast structures are able to recover quickly after storms. Because the precast is mold/mildew resistant, it is able to not only withstand flooding, but recover without long lasting damage. This resiliency translates into structures that last longer and withstand much more than timber structure which have to be replace more frequently and end up causing more materials to be sent to the landfill.

The Takeaway

Improvements in both the timber and precast industries could mean larger impacts on reducing global carbon emissions for the construction industry as a whole.  Working together they could significantly cut their emissions together and provide designers solutions that meet their clients long-term carbon and sustainability needs.

Energy Efficiency and Precast Concrete

Environmental discussions are becoming more and more important and precast has become apart of those discussions with its ability to act as an energy efficient construction solution.  Through its numerous design benefits, precast can be the go to solution for clients looking to meet sustainability goals and reduce their impact on the environment.

Because concrete has a higher density, it has the capacity to absorb and store larger quantities of heat than other materials such as wood.  Concrete reacts very slowly to changes in temperature which reduces heating and cooling loads. During the day, the concrete slowly heats up using the heat from the outside environment and then slowly releases this heat during the night using natural ventilation.  The result is flatter swings in temperature and energy savings of up to 25%. Thermal mass is an important element to precast’s ability to provide more energy efficient to a structure.  

Using precast concrete structural wall panels with architectural finishes reduces the redundancy that comes with traditional cavity wall systems.  Precast concrete is an all-in-one construction material that provides a moisture barrier, fire resistance, noise cancellation, and insulation wall without the need for additional materials. It also is able to maximize its thermal properties by delaying heating/cooling requirements which can reduce strain on HVAC equipment over the life of the structure. 

When a building is erected using precast concrete, the building is enclosed which limits moisture and mold during construction. Also, precast concrete is an efficient construction material from its construction stage throughout the operation of the building.  Hard finished surfaces are easy to maintain and precast is the perfect material for an organized, time and labor saving, cost-effective building system. 

---

The resources below discuss more about the efficiency of precast concrete

---

 New Orleans BioInnovation Center

The BioInnovation Center was the first laboratory building in Louisiana to achieve LEED Gold certification as a result of various sustainable and efficiency features.

FIU Student Academic Center

The design team of the precast FIU Student Academic Center was able to balance nature light with temperature, limiting the native heat and keeping temperatures cool.

Precast Plant Safety

Beautiful precast structures wow and amaze us. The versatility and unique adaptability of precast concrete allows for high impact designs, as well as straightforward brute strength building components. Regardless of the design or product being produced, all precast building materials get their start in a manufacturing facility at the hands of highly skilled producers. The “day-in-day-out”  production process is shrouded in a blanket  of safety protocols intended to minimize or eliminate worker injury. 

SAFETY IS EVERYONE'S RESPONSIBILITY

*Management’s Role: Supervisors and managers bear the enormous responsibility of ensuring that crews are safe at all times. Oftentimes, a company Safety Manager will head the training, both initial and on-going” for safety issues in precast plants. They will oversee that all mandates are being followed and provide company-specific training. Many companies kick-off their day with a “toolbox talk” which serves as a brief meeting to highlight areas of concerns and provide daily reminders about safety rules. 

*Employee’s Role:  Employees often “police” themselves and remind fellow workers when they observe safety protocols not being followed. Some companies provide different colored hardhats to new employees so they are easy to spot and special attention can be paid to them as they become acclimated to the plant environment. It is the employees responsibility to familiarize themselves with the employee handbook and the safety plans for the plant. 

AREAS OF CONCERN IN A PRECAST PLANT

The Plant

Is PPE being worn? Gloves, steel toed boots, ear protection, specially fitted sandblasting suits etc. are all items designed to protect workers from chemical exposure and silica exposure as they perform their duties.

Is the machinery being properly maintained? Machine maintenance not only ensures a breakdown doesn’t inhibit the production process but it also ensures that workers are not injured while machines are in use. Items such as back-up alarms as well as using “lock-out-tag-out” systems are in place to provide an additional layer of safety at the plant.

Is the plant neat and orderly? Slips and falls are easily avoided when the plant is free from spilled liquids and items left laying around. 

The Yard

Do yard employees have situational awareness? As cranes and trucks move about the storage yard, workers are at increased risk of injury if they are not keenly aware of their surroundings. 

Are lifts being used at proper capacity? Exceeding capacity of machines, whether in the plant or in the yard, can result in dangerous situations. It is the responsibility of both management and workers to ensure that unsafe practices are not happening with the goal of saving time.

The Erection Crew

Is the crew on the jobsite practicing safety? Because precast producers are often subcontractors for a general contractor, many times a safety plan will be requested by the general contractor addressing how the precast products will be handled and erected safelyon the jobsite. 

The Trucking

Is the movement of the product from plant to jobsite safe? From loading of the trucks to tie down of products, safety begins before the precast components leave the yard. Once loaded, products must be trucked on public roadways and unloaded safely on the site. Sometimes special permits are required for the trucking of extra large components. 

Safety is everyone’s concern. It is imperative that time and energy are devoted to processes and protocols that keep workers safe and injury free. The Optimum Safety Group offers beneficial safety guidelines to PCI members and can be found at www.pci.org. OSHA also has a wealth of information regarding silica and other pertinent topics. 

Precast Automation

Labor shortages are wreaking havoc across the nation. The precast manufacturing industry, along with other industries, is actively taking steps to address the issue while consistently maintaining a reputation for high quality. A solution has been found with the adoption of automation. Automation in precast plants ensures a steady and uninterrupted flow of product will be delivered in an efficient and controlled manner. 

Precast automation boosts several benefits including offering high quality products, improved efficiency, increased safety, and reduced manpower.  These benefits offer improved work conditions for employees and keep products rolling out the door in a timely manner.

Greater Consistency/High Quality

Human error is impossible to avoid.  People make mistakes and those mistakes can be anything from something small with little impact to something large scale mistakes that affects budgets and schedules.  Automated machines and computer programs don’t make mistakes which equates into less budget busting errors.

Increased Efficiency/Less Time Consuming

Automated machines and processes can be tweaked to achieve the highest efficiency possible and then that efficiency can be maintained day in and day out. Precast automation allows for accelerated production schedules thus maximizing the manufacturing potential of the plant.

Safer for Workers

Manufacturing precast can be a difficult job even for the most experienced worker.  Health risks associated with silica dust, noise pollution, and muscle strains/sprains are risks that precasters work to avoid on a daily basis.  Automation helps cut down on risks posed to workers and improves the overall safety of the environment. 

Reduced Labor Intensity for Workers

Automated precast processes means less workers are needed to manufacture precast products. Processes that traditionally required 10 workers could potentially only take 3 using automation. The reduction in workforce provides a cost saving to precast manufacturers that is passed on through more competitive market prices for precast products. It is important to note that although automation reduces the number of overall workers, there will always be need for personnel to program and run the machines. Precast automation is an opportunity for precasters to employ a higher caliber of laborer at a higher wages who uses more brain power and less brute force.

The automated production of precast concrete is a riveting process to witness.  Vollert Precast recorded the automated production of double walls and floor slabs showing how automation can be used in conjunction with workers to create precast components.

As with any new innovation, automation has both positives and negatives to consider. The downside of precast automation includes the significant upfront costs associated with either building a new production plant dedicated for the automation or upgrading an existing facility.  However, the long-term benefit of precast automation lies in money saved through a reduced workforce and accelerated production potential. 

Precast Double Tees

As one of the most widely used precast components in North America, the double tee is a versatile and cost-effective precast product that can be used for a variety of projects. But what is the double tee and what makes this precast component so popular?

What is a precast double tee?

Double tee precast components tend to be used for larger structures such as parking garages or large buildings, but they can be used for other projects including shorter bridges and highway structures. The design allows them to offer wide uninterrupted spans while supporting higher loads.

The shape of the double tee resembles its name and looks like two capital “T”s put side by side. Double tees are prestressed prior to casting with prestressing tendons which consist of high tensile strength cables. They can be used as both horizontal and vertical load-bearing members.

---

What are the benefits of Double Tees?

Precast double tees benefit from the same attributes as other precast components including resistance to extreme weather, minimal required maintenance, and cost-effectiveness in comparison to other construction materials. In addition, double tees also have their own specific benefit which is the ability to provide long, clear spans while still supporting high loads.

Precast double tees can be designed for spans reaching up to 100 feet. This is an important benefit for structures such as bridges which span over wide areas or buildings created with open-concept designs.

NPCA tested the strength of a precast double tee beam against multiple 4,400 lb barriers placed on top. What happened? Watch the video to find out!

---

Camp Shelby Training Center

The Camp Shelby Operational Readiness Training Center is an all precast facility whose construction included the use of 163 double tees. Precast was used to create the facility to meet occupant load requirements.

The Park at South Market

The Park at South Market is an excellent example of the most common use of double tee precast beams. The project included 286 12’ double tee beams integral to the construction of parking garage located in New Orleans, LA.

Residential Precast

Residential projects use of precast to meet high-performance goals. From single-family homes to large-scale condos, precast is the right choice for constructing residential facilities.

Credit: Jack Jennings & Sons

Single and Multi-Family

Precast is definitely not the first construction material people think of when it comes to single and multi-family homes, but the benefits it provides to homeowners makes it a valuable option. Precast offers several security benefits to homeowners including resistance to extreme weather events and inherent fire and storm protection. Precast is also cost-effective over time because of its energy efficiency and lower maintenance costs. Homeowners can also take advantage of the aesthetic versatility of precast to design a home that matches their specific design taste. Accelerated building schedules allow precast to be erected faster than homes designed with traditional building materials . Multi-family homes benefit from the noise-canceling qualities precast offers. In the end, precast is a great alternative to stick-built construction for homeowners who are looking for a more resilient, durable solution that saves money over the life of the home.

Credit: Kloudvue Koncepts

Student Housing

Student housing facilities face many demands during their lifetimes. Decades of students moving in and out translates into a lot of wear and tear on a structure. Durable construction materials that meet the challenges of student populations are key, along with safe and comfortable environments that allow for flexibility. Precast meets these demands because it is an inherently durable, resilient material that provides protection from storms, fires, and other threats. Precast offers the reduction in noise pollution that can occur in crowded residential spaces. Lower life cycle maintenance costs provides value to the university in the long run. Additionally, schools are often challenged with accelerated schedules to complete construction projects while students are away and precast is able to meet these accelerated schedules without issue.

Commercial Hotels and Condos

Hotels and condos take a lot of abuse from guests and demand durable options for construction. Precast provides building owners with numerous aesthetic and structural options to meet their project goals for beautiful and functional high residency structures. Precast offers sound insulation, resiliency, and protection of guests from extreme events such as weather and fires. Precast hotels and condos work well in all geographic areas and serve residents with the comfort and safety they expect.

Credit: Scott Shigley

Senior Living

Senior Living centers are designed with the priority of creating comfortable environments for occupants in a budget-friendly manner. Precast is able to help senior living facilities optimize their buildings with aesthetic and structural versatility. High-performance precast is great for both low and high-rise structures and is a durable, resilient material that can be constructed quickly without sacrificing quality.

Case Study

The One South First mixed-use building projects from Gate Precast showcases just how versatile precast can be for residential projects. Using precast, designers reused a 22-story commercial structure and transformed it into a contemporary residential building. Precast was used for the facade to pay homage to the original use of the building as a Domino Sugar factory.

Ultra-High Performance Concrete

Ultra-High Performance Concrete or UHPC is a type of concrete that has steadily grown in popularity due to its increased durability and strength over traditional concrete. The US Army Corps of Engineers first used UHPC in the 1980’s, but it wasn’t until 2000 that it became commercially available in the US. Since then, more professionals, including PCI precast producers, have been using UHPC in projects ranging from bridges to buildings.

What is UHPC?

UHPC is characterized by several things including ultra-high compressive strength, high pre-cracking, and post-cracking tensile strength, and enhanced durability due to high density and discontinuous port structure. While there are numerous advantages that UHPC brings to projects that will be covered later in this article, the overall benefit of UHPC is the elimination of reinforcing steel and the material’s ability to self-compact.

UHPC is made by combining portland cement, supplementary cementitious materials, reactive powers, limestone/quartz, fine sand, water reducers, and water. Fibers are included in the mix to help provide the strength and durability that UHPC is known for. Fibers can range from brass-coated thin wire to glass fibers mainly used for architectural applications.

UHPC can come in a prepackaged mixture or as local material-based mixtures. Prepackaged UHPC mixtures have several benefits including more selective raw materials, assured batching consistency, and reduced batching times. UHPC made from local materials has slightly different benefits such as lower cost and the ability to be tailored to project needs, but it requires local expertise and verification testing.

---

PCI has a pre-recorded UHPC webinar free to view which gives a more in-depth description of UHPC at the link below.

---

What are the benefits?

UHPC’s durability has been extensively tested and it has been found to respond exceedingly well to extreme conditions that standard concrete struggles with. UHPC’s testing has been completed in three main areas and includes:

• Freeze/thaw resistance: Testing has shown UHPC retained 100% of its material properties after 600 thaw/freeze cycles.

• Chloride permeability: Testing has shown UHPC has extremely low chloride migration, less than 10% of normal concrete.

• Abrasion resistance: Testing has shown UHPC has 2x the abrasion resistance of normal concrete.

Aside from its durability benefits, UHPC brings a host of other advantages to projects. UHPC can be produced using local materials which reduce its cost. Overall, UHPC is also a lighter material per foot which results in less expensive shipping and spans can be designed for longer lengths. UHPC isn’t restricted to structural precast components; it can be designed for architectural cladding as well. Best of all, because of UHPC’s durability, it has about double the lifespan of standard concrete which makes it a better choice for the environment in the long run.

Cor-Tuf, a PCI Associate member of FPCA, has created and tested their own UHPC mixture and provides precast components to the Florida region. Below is a video they created that shows multiple tests of their UHPC piling and demonstrates just how durable and strong UHPC components can be.

PCI Foundation Studios

One of the missions of the PCI Foundation is to help support and fund precast studios at universities across the country.  Studios are important tools to help future engineers and architects learn what precast is and the benefits it can bring to projects they will design in the future.

About the PCI Foundation

The PCI Foundation has been providing curriculum development grants to universities of architecture, engineering, and construction management for 20 years. This funding gives professors the ability to partner with local precast producers, engineers, and architects to create unique precast content. These partnerships foster relationships between the precast industry, university professors and future industry leaders. 

PCI Studios

Since 2007, the PCI Foundation began sponsoring learning studios at universities with majors in engineering, construction management, bridges, and architecture. The PCI Foundation assists with funding  programs for several years before universities are asked to begin supporting the projects on their own.  To date, research has shown a high ROI on program continuation after PCI has passed the program off to universities.  

So far more than 4,000 students have participated in a PCI Studio at 31 universities.

How to Apply for a PCI Studio

For schools interested in starting a PCI Studio, there is a simple process to follow to apply for a grant.  After reviewing the Proposal Guidelines and Getting Started guidelines to fully understand the application requirements, schools can reach out to the PCI Foundation to discuss the next steps and begin their proposal process.  An advisory committee is put in place for applications to help them stay on track during the process. Professors work with a precast partner during the writing of their proposal.

PCI Gulf South Studios

PCI Gulf South has partnered with several studios in the Gulf South region to help provide precast knowledge to future engineers and architects.

Under the direction of Charles Jones, RA at Tulane School of Architecture, future designers enrolled in the university use the studio to tackle environmental issues using precast concrete products.

As a recipient of a newly awarded PCI Foundation studio grant, Assistant Professor Alexis Gregory has begun to immerse her students in the vast opportunities precast offers to the design community.

In August of 2020, the University of Alabama was awarded a studio grant for a 4-year studio focused on precast and prestressed concrete education.

McNeese State University was recently awarded a PCI Foundation Studio. The studio program, which is composed of industry partners and academia, will focus on precast products and their use in the petrochemical industry.

Precast Concrete and Thermal Mass

What is Thermal Mass?

Thermal mass is described as the inherent property of a material to absorb heat.  A material with a high thermal mass is able to moderate temperatures inside a facility throughout the day.

Because concrete has a higher density, it has the capacity to absorb and store larger quantities of heat than other materials such as wood.  Concrete reacts very slowly to changes in temperature which reduces heating and cooling loads. During the day, the concrete slowly heats up using the heat from the outside environment and then slowly releases this heat during the night using natural ventilation.  The result is flatter swings in temperature and energy savings of up to 25%.

Benefits of Precast

Energy Saving Benefits

Thermal mass is affected by temperature both inside, from things such as indoor lighting or heat transferring through windows, and outside, from the climate.  When a building’s envelope is constructed from precast with the interior concrete exposed and not covered by insulation or drywall, the concrete is able to absorb the heat from inside and reduce cooling costs.

Reduce Urban Heat-Island Effect with Lighter Colors

Lighter-colored concrete will have a higher amount of solar radiation reflected off its surface and reduce the amount of urban heat-island effect.  Depending on the needs of the facility, lower amounts of reflection might actually be needed in order to absorb more heat from the outside of the structure.  Designs can include different colored surfaces for walls facing different directions to achieve the best energy conserving arrangement.

Reduced Uncontrolled Air Infiltration

An important part of thermal mass is the air infiltration of a building, as well as its energy-saving benefits.  The connection between panels is important for reducing uncontrolled air infiltration and helps minimize heating and cooling costs.  Larger precast panels have minimal joints further reducing this issue.

---

Looking for more information about thermal mass? Check out some of our free resources below!

---

Case Studies

Statue of Liberty Museum
New York, NY
High Concrete Group
The high thermal mass of the concrete panels helps maintain interior temperatures and minimizes the effects of outdoor temperature swings. Additionally, special connection details minimize thermal bridging between interior and exterior building components.

New Orleans BioInnovation Center
New Orleans, LA
Jackson Precast
Slenderwall precast provides a consistent and controlled building envelope through the use of closed-cell foam insulation which acts as a vapor barrier and contributes to the air/water tightness of the panels.

Resources:

https://precast.org/2011/08/thermal-mass/
https://www.concretecentre.com/Performance-Sustainability/Thermal-Mass.aspx
https://info.wellsconcrete.com/thermal_testing

Schools Tackle Storm Resistance

Precast concrete is an inherently resilient building material and has the proven ability to provide protection against extreme weather events such as tornadoes, hurricanes and earthquakes. Because of its resiliency, precast is often used in FEMA shelters and when used in schools, can create a dual purpose for the facility by enabling it to act as a storm shelter for the community. Many districts apply for FEMA funding grants to assist with the cost of new construction and the new construction must adhere to the types of requirements that precast concrete naturally addresses (i.e. IBC wind rating to 250 mph).

View fullsize

---

This cutaway BIM drawing shows a gymnasium with a total-precast concrete structural system designed as a FEMA safe room for the Marquand Zion School District in Mar-quand, Mo. The 1,400-square-foot, two-story addition on the side of the 8,000-square foot gym qualifies as part of the safe room but contains restrooms below and mechanical systems above that feed into the gym. Photo: Toth and Associates

Using Precast For School Storm Shelters

Through the use of precast, designers are able to develop hardened areas and safe zones within schools that students and faculty members can use when extreme weather events occur.  Total precast solutions are the best solution for resistance to tornadoes, hurricanes, and extreme thunderstorms. The idea of safe rooms tends to be overlooked when designing school facilities because of budget constraints along with the assumption that these structures will have a “bunker” appearance.  However, there have been a number of successfully constructed facilities, such as gyms, classrooms, and performing art centers, that meet the needs of safe rooms while avoiding the traditional look of a bunker.

---

Tornadoes

In the past, most people have associated the Midwest with Tornado Alley. However, in recent years Tornado Alley has shifted further east and encompasses a number of other states in the danger zone including the Gulf South region.  These “Dixie Alley” tornados are more dangerous because they occur in greater populated areas and tend to be more costly in property damage. Precast can act as a solution to this problem by helping schools in these danger prone areas develop wind resistant facilities that can withstand tornados. Precast has been impact tested and proven to provide resistance to flying debris associated with tornados.

Twisters occur around the world, but the United States is a major hotspot, with about a thousand tornadoes every year. Research has shown that Dixie Alley is now a more frequent destination of these violent storms. Photo: Federal Emergency Management Agency.

---

Source: The Weather Channel

Hurricanes

Hurricanes tend to be more complex than tornadoes and therefore require specific design specifications to withstand the variety of forces they can produce.  Hurricanes produce not only high winds, and occasionally tornados, but also high impact waves and tremendous amounts of rain and surge.  Structures have to be built to withstand these events and protect the people inside.  The Gulf South region has dealt with several major hurricanes over the last decade.  

Several school facilities within the region, such as St. Vincent’s in Long Beach, MS, decided to adopt a precast solution after losing their facilities to hurricanes.

Precast provides protection from high winds, storm surge, and scour. In the aftermath of a hurricane, precast also prevents mold from developing on its surface and fire resistance making it easier to rebuild quicker and cheaper once the storm has passed.

---

The Robert J Curry Public Safety Center in Gulfport, MS replaced the original Gulfport Police Station destroyed by Hurricane Katrina.  The new facility has an architectural precast exterior wall system that meets FEMA 361 design and construction guidelines and can withstand 200 MPH winds.

After being destroyed by Hurricane Katrina, St. Thomas and St. Paul Elementary Schools decided to merge and rebuild using a total precast system solution.  Precast was chosen because of its resiliency.

---

Unfortunately, extreme weather has become the new normal is many areas of the country. Schools are turning to building materials that provide the durability and resiliency necessary to protect students and the community. Precast building materials protect during the storm and expedite recovery after the storm by creating structures that survive intact.

Precast Educational Athletic Facilities

Athletic facilities are unique structures in the fact that they need to house thousands of people for major events sometimes multiple times a week while lasting through years of continued use and being exposed to the elements. To achieve this level of capability, athletic facilities need to be built to last using high-quality materials that require little maintenance. Precast is the perfect solution for these facilities to help them stand a lifetime and be prominent structures on school campuses.

Little Maintenance

Precast inherently requires little maintenance once constructed. Structures made from precast can last decades before any kind of maintenance is needed. There are also innovative techniques such as the use of self-cleaning admixtures which keep precast looking new without any additional effort.

High Durability

Precast athletic facilities have several advantages regarding durability.  Outside facilities such as stadiums and bleachers will be able to withstand extreme weather events such as snow, rain, high heat, seismic events, and hurricanes without sacrificing their structural stability.  Precast also helps these facilities hold up against constant wear and tear from students and event attendees.  

Other athletic facilities such as indoor gyms can not only be used for athletic events but also double as storm shelters when built with precast.  They can serve as FEMA centers in areas where extreme weather is common and can be used to protect both students and the surrounding community.

Cost-Benefit

Schools often have very tight budgets and are looking to get the most out of their construction projects. Although precast can be slightly more expensive in the short term, in the long term the benefits greatly outweigh the initial cost. Schools will save money in construction costs, maintenance, and the reduced need for renovations. Because precast structures last decades, schools won’t need to consider replacing these structures for many years. Also, precast can help schools be more energy-efficient helping them cut costs on heating and cooling.

Safety

Schools across the country put a lot of value on the safety they can bring to their students. Precast athletic facilities can help schools provide the level of safety they are looking for. Precast is inherently fire resistant and can be built to help stop the spread of fires within the facilities should they happen. Designers can also work with precast to help create safe spaces and restricted lines of sight in the event of unauthorized personnel on campus.

Case Studies

Producers in the PCI Gulf South regions have worked with both K-12 and high educational clients to create athletic facilities that met their unique needs.

LSU Basketball Practice Facility

This project consisted of a 58,960 gross square foot addition to the existing Division 1 University Basketball Arena. Precast was used to create a building form that acted as a natural extension to the futuristic form of the original arena and was used alongside a self-cleaning photocatalytic titanium dioxide admixture, to resist the impact of the adverse climate.

Dudy Noble Field

Built in the 1980s, MSU’s Dudy Noble Field was in need of modern renovations. 99 precast panels covering almost 8,000 SF with architectural precast concrete were used with an acid-etched finish to mimic white limestone.

LSU Tiger Stadium

21 pylons to act as gateways and ticket collection areas for the LSU Tiger Stadium. Precast helped complete the project on a tight project schedule, on a constricted site, with major architectural exposure.

Precast School Renovations and Additions

Educational buildings are in constant use and experience heavier activity levels than most buildings. According to available data, the average age of the 99,000 public schools in the United States is 42 years old. When a school building reaches 20 to 30 years in age, frequent repairs to equipment occur. Buildings that reach 30-40 years, begin to require replacement of equipment and structural elements such as roofs. School buildings in the 40 to 60 year range start to rapidly deteriorate and many school buildings are abandoned after 60 years of age.

Based on these statistics, it can be assumed that there are a large number of K-12 school facilities in the United States that are in desperate need of repairs. Not only are these facilities in need of renovations/repair/replacement, but older schools tend to serve a greater number of children in poverty. This correlation is rooted in budget constraints often faced in low-income areas of the country. The 21st Century School Fund projected that schools in 2018 would need to spend on average $196 million to update facilities simply to accommodate new students, a number which has increased over the last few years.

How Can Precast Help

Where does precast fit into this equation and how can precast assist with renovations/repairs/replacements that will serve the student population with minimal maintenance for decades to come? 

Precast provides a building solution that K-12 schools can utilize to create modern, low maintenance renovations to existing buildings. Precast structures have an adaptable and versatile design capability that can be blended with existing structures while providing safe and durable spaces for students.

Accelerated Schedules

A major benefit of using precast is the ability of precasters to meet tight project schedules. Oftentimes, schools cannot close during the school year for renovations and are forced to complete construction during breaks or over the summer months.  Precast components are manufactured offsite and arrive ready to be erected. Depending on the number of precast components, it can take as little as a few days/weeks to get everything in place, greatly accelerating construction schedules.  An additional benefit to the offsite construction of precast is that fewer people and equipment are required on-site. 

Match the look of existing materials/styles

Precast is a versatile building product that offers an array of textures, colors, and styles.  Precast has the ability to be matched to existing materials such as stone or brick through the use of brick inlays or specialized formliners. Precasters are able to use forms to make unique designs such as mascots or text. With the versatility of precast, schools have the option to design renovations that match existing architecture or create unique looking additions.

Fit in tight urban or project sites

As previously mentioned,  precast components are manufactured offsite in a quality controlled environment by skilled and experienced producers. The offsite process equates to less equipment and personnel on the job site and no delays in production due to inclement weather.  This also means that tight project sites, like those often found in urban areas, are no challenge for precast.  The precast erection schedule is highly choreographed so components arrive at the site ready to be lifted into place which minimizes truck traffic and the need for a large staging area at the site.

---

Ascent Summer 2018

PCI published an entire Ascent issue on the role precast plays in K-12 schools and how cutting edge designs meet the schedule and budget needs of schools around the country.

Read Issue

---

Case Studies

Charles Progressive Academy

The decision was made in 2011 to preserve the mid-century building with thoughtful additions conveying the significance of its architectural and social merits. The additions utilized precast concrete that saved time and money and resolved a number of design issues.

Summit Country Day School Addition

The solution for the new construction of the school’s addition was precast executed under an IPD-methodology. The existing architecture from 1888 was matched to perfection by a tightly integrated team, erecting a five-story structure and envelope in 21 days.

---

As school districts continue to explore solutions for aging structures that meet student demands while fitting budget and time constraints, precast is the answer.  The versatility, durability, and efficiency of precast “checks off all the boxes” while providing an aesthetically pleasing product that will stand for decades to come.

Architectural Precast & Historic Schools

Architectural Precast Mimics Historic Schools

The US is home to tens of thousands of historic buildings of which thousands are school facilities.  One of the oldest school facilities currently in use in the United States is the Boston Latin School is Boston Massachusetts which was created in 1635. Needless to say, schools take pride in their heritage and strive to preserve the historic structures on campus.  Historic schools face challenges when they need to expand or adapt. This is where the versatility of precast is the perfect solution! 

The Needs of Historical Schools

Historic schools often face challenges of “modernizing” while maintaining the historic appearance. Improving energy usage, creating flexible and adaptable learning spaces and addressing health /safety for occupants is the same for a historic school as it is for a contemporary designed school but with the added need to match the historic aesthetic of the existing structures. 

Retaining Historic Individuality

Historic schools showcase the rich history of the campus and typically employ architecture from various time periods. Names, dates and images are often incorporated into the long-standing structures as monuments to the past. The infinite options available with the use of precast concrete allows designers to pick up where history left off, thus maintaining a seamless appearance. 

Creating Buildings that Look Exactly Like Original Buildings

Sometimes older buildings have to be replaced. In some cases, schools desire to replicate the original structure with a new one. Precast versatility allows for close duplication of existing structures to include such things as matching color, texture and even brick. 

Creating Additions to Blend with Existing Architecture

As school demand grows larger, facilities are forced to grow larger to meet that demand. Historic schools can work with designers to create additions that blend into the existing architecture. The unique challenge for designers is the availability of materials to match existing structures. 

How can precast help?

Through the use of pigments, aggregates, acid etching, brick inlays, specialized formliners and more, precast concrete building components are manufactured by highly skilled precast producers to bring a design to life. Whether the design calls for a brand new look or the replication of an existing design, precast has it covered. 

---

Gate Precast provided precast to achieve the look of 100-year old limestone for the St. George Catholic Church, making the new precast components indistinguishable from the original limestone.

Formliners are reusable forms that can recreate patterns such as brick, stone, etc on concrete panels.  Read more about the creative freedom of formliners on our blog, Formliners and the Versatility of Precast Concrete.

Below are just a few examples of some of the possibilities!

Case Studies

The Charleston Progressive Academy was built in 1955 and the school wanted to retain its historic identity while providing a modern facility for the students.  The decision was made to use precast to help preserve the mid-century building with thoughtful additions.

LSU was looking for an addition to their 1970s basketball arena that would preserve the iconic structure which is located in tight project site.  Precast was used to build the new addition in a fraction of the space.

Historical schools face a variety of issues when tackling a new construction project. Adding precast building materials into the design aids in achieving the desired end result while also providing a resilient, versatile, and efficient structure that will stand for years to come.

Schools and Precast in Urban Environments

The United States contains over 13,000 school districts that are classified as “urban”. Those districts serve over 49 million students.  These school districts have a variety of facilities that require routine maintenance in order to perform efficiently for the student body.  As funding and societal issues become more pressing, maintaining a functioning facility is sometimes pushed aside.

School facilities constructed with precast require less maintenance in the long term and are smart investments. Boasting numerous advantages, precast limits the need for ongoing facilities spending and allows districts to direct more funds toward the education of the student.

How does precast help?

Offsite construction

Precast is produced in offsite facilities, thus freeing up space on the job site.  Designed and produced in quality controlled environments, schools can rest assured the precast components used to build their facilities have undergone a rigorous inspection.

Quick erection

Because precast is produced offsite, it arrives at the job site ready to be put into place.  Precasters understand that schools often require accelerated schedules in order to complete work in between the times when students are present.  Precast can be erected in as quickly as a few days depending on the size and complexity of the structure and can be erected in all types of weather.

Blend into surrounding environment

Precast can be designed to match existing or surrounding structures. With a variety of textures, colors, and designs available, precast producers design precast components that help schools blend into  urban surroundings or with other buildings on  campus.

Less disruption for surround structures

With less personnel and equipment needed to erect precast on site, precast provides less disruptions for surrounding structures and neighbors.  Precast is erected quickly meaning loud equipment won’t be on site for long periods of time, thus reducing noise pollution to the surrounding community.

Unique Designs

Schools that wish to add a unique look to their facilities can count on precast to deliver.  Precast can be designed  in all shapes, sizes, and colors and design details such as text or images can be incorporated into the components through the use of specialized formliners. 

Provides Support to Security Efforts

Precast schools provide the advantage of  passive security.  Through long site lines and secure access points,  an impenetrable building that is easier to monitor is achieved.

Along with these specific benefits, precast also offers other benefits to schools such as fire, blast, and storm resistance, as well as  mold resistance and superior resiliency and sustainability.

---

Take a look at some of our additional blogs that illustrate why precast is the right choice for schools.

---

Case Studies

Charleston Progressive Academy

The Charleston Progressive Academy chose precast to help preserve the historic school which is located in an urban neighborhood and had  a tight construction schedule.

Lehigh Valley Charter High School for the Arts

The Lehigh Valley Charter High School  used precast to construct its 83,000 SF facility in downtown Bethlehem, PA. The precast components were erected in January during inclement weather in order to meet the August school opening deadline.

---

While the focus is on improving the lives of students, schools need not be forced to with continual repairs and renovations.  Precast, as a primary building material, offers school designers the option that districts need to stretch budget dollars and provide safe, secure and high functioning structures that meet high demands decades to come. 

---

Want more? Check out PCI Gulf South’s technical resources on school facilities on our Institutional webpage.

The Value in a Precast School Structure

The investment in education in the US comes with a phenomenal price tag. A look at both the public and the private school sectors reveals where the bulk of money is spent to support the education of our youth. 

Current Environment for Schools

A closer look at the public/private school sector reveals there are roughly 13,506 public school districts in the US with a whopping 130,930 buildings currently in use by school children in K-12. Additionally, there are another 34,576 private schools in the US that serve approximately 25% of the school age population and are mostly religiously affiliated. The median age of the buildings in use are 44 years old and have not undergone a major renovation in the last 12 years. 

School budgets are stretched thin each year as taxpayers resist increases and expenses continue to climb. The largest expenditures fall into the categories of:

• Maintenance

• Infrastructure

• Capital Work/Improvements

• Staff Salaries/Benefits

• Transportation

• Utilities

---

How Can Precast Concrete Play a Role in Easing Budget Woes for School Districts?

The resurgence of precast into the school market started in 2000 when labor shortages placed a crunch on the timelines for school projects. The advancements in precast building products gained a second look of designers because of the lengthy list of advantages precast brings to a project. The desire of school administrators to steer away from traditional 30 student square classrooms located on either side of a main hallway opened the door for the precast community to demonstrate the tremendous versatility and adaptability of precast building systems. With the ability to meet codes in any part of the country, precast components are also the answer to concerns about thermal efficiency, safety from natural disasters, speedy project completion schedules and long-term life cycle cost management issues. Although it’s hard to “teach an old dog a new trick” and schools tend to repeat the same building styles they currently have, specifiers are consistently seeking ways to create learning environments to meet the changing demands of the student population in a sustainable and efficient manner all with a tight grip on the limited funds they have to work with.

---

Why Is Precast The Right Choice for Schools? 

Accelerated Schedules

Offsite manufacturing of precast building systems allows for a high quality product that arrives to the site ready to be installed. The project is not hindered by weather challenges and requires only minimal laborers onsite. 

Storm Shelters/Weather Events

Providing a safe learning environment that can pull double duty as a community storm shelter is the beauty of a multi-use precast design. Many districts apply for FEMA funding grants to assist with the cost of new construction. The new construction must adhere to the types of requirements that precast concrete naturally addresses (i.e. IBC wind rating to 250 mph).

LEED/Sustainability 

Educational facilities designed to maximize thermal efficiency and lessen environmental impacts have gained momentum with sustainable considerations woven into the design.  The PCI Gulf South blog on LEED and precast discusses how precast concrete excels at meeting LEED requirements.

Architectural Precast can match Historic Schools

Oftentimes, districts choose to add an addition to an existing building in lieu of a completely new structure. Through the use of such things as specialized formliners, color and texture options, thin brick inlays, etc precast wall panels can be manufactured to replicate the look of an existing structure for a seamless appearance. 

Renovations

The following Ascent issue highlights some of the many ways precast concrete offers school districts the qualities they desire for new projects. From matching historical qualities to budget considerations to increased speed of construction...each project brings a unique set of challenges that precast concrete addresses with efficiency and durability. 

Fire Resistance

Precast concrete structures offer premier fire resistance and create an environment that is safer for occupants and safer for first responders in the event a fire does break out. Precast keeps fire compartmentalized and will not burn unlike competing timber building materials. 

Security

Schools constructed with precast concrete allow for design options that maximize security by providing long site lines and secure access points. Each design caters to the needs of the school with an impenetrable building product. 

Athletic Facilities

Stadiums, training facilities and arenas are areas of extreme use and abuse. Precast concrete systems handle the human element as well as the natural elements and perform exceptionally well in all climates and geographic locations 

Urban Environments

School construction in tight urban areas pose challenges to the “traditional” style of building. However, precast components arrive at the site ready to erect with minimal laborers and minimal staging area, thus offering less disruption to existing schools as they remain functional throughout the process.

Read more about precast in urban spaces in our blog below.

Life Cost Analysis

When considering the long-term costs associated with operating a school, the savings realized through the use of a precast building system can be found through lower maintenance costs and reduced heating/cooling costs among other things.

Our blog, Think Long Term Choose Precast Concrete discusses this idea in more detail.

---

Technical Resources

Ascent offers an invaluable resource for designing educational facilities with precast. Technical information, along with project examples are included here. Click on an article to read more information.

---

Case Study

The Charleston Progressive Academy reaped the benefits of using precast on their project. With the expertise of Tindall, leading manufacturers of precast concrete building components, the Charleston Progressive Academy had the project completed in under one year, saved tens of thousands of dollars in construction costs, and had  their design completed in a tight urban area.

---

School projects deserve to be designed to make the very best use of the dollars invested in them. Precast concrete systems offer the full package of durability, safety, economy, versatility, adaptability and so much more. This is HOW PRECAST BUILDS. 

Precast and Sustainability

Building trends evolve over time and one of the more noteworthy changes the industry has seen in recent decades is the creation of the LEED certification rating system. This “badge of honor” is earned through the design of structures that address environmental issues in a mindful manner. The LEED Rating system was developed by the non-profit, non-governmental organization known as the United States Green Building Council (USGBC). The organization has developed this voluntary rating system to aid designers. Oftentimes, public projects will mandate that a structure must attain a specific level of LEED certification but private projects have the option to pursue a rating if desired. 

Based on a point system, the more points earned the higher the level achieved and the greater the reward. The points are earned resource-efficient buildings and healthy spaces for occupants.

So what does any of that have to do with precast? Precast concrete building components possess some of the most inherently environmentally friendly and resource friendly attributes of any building material available. The sustainability factor alone of projects constructed with precast well outperforms competing materials.  

---

SUSTAINABILITY

Thermal efficiency: Edge-to-edge, top-to-bottom rigid insulation can be used within a relatively thin wall, providing a high effective R value. The thermal mass of the concrete provides an added benefit by slowing heat transmission through the wall, flattening out temperature swings. Visit the link for further details on precast insulated wall panels 

Reduced Life Cycle/Maintenance Costs: Over the life of the structure, precast concrete costs less to maintain and lasts longer than other traditional building materials resulting in less need for repair/replacement. Building a structure that lasts decades with little additional maintenance versus building a structure that requires on-going upkeep makes sense and saves money. Couple this with the integration of recycled materials in the manufacturing process and the savings is even greater. 

Energy Savings: Aside from the thermal mass of concrete itself, walls are often insulated with materials such as polystyrene to maximize the R-value. They act as a thick insulated barrier against summer sun and winter cold. This characteristic allows for a smaller investment in HVAC equipment on the front end and eases the load on HVAC systems over the long haul, resulting in lower operating costs.

Durability in Challenging Environments

Whether the issue is hurricanes, flooding or tornadoes, the “tough as nails” properties of precast concrete addresses the issue with an inherent durability unmatched by competing building materials. Dig further into the advantages of precast concrete as a primary building material at both resources at the links below.  Sustainability, life-cycle considerations, and environmental product declarations make the case for why pracast is a slam dunk in areas prone to repeated extreme weather challenges. 

---

---

Current Innovations

Carbon Neutral Concrete

In an attempt to reduce the amount of carbon dioxide that is produced during the production of cement, a key ingredient in concrete, substantial resources have been directed toward solutions to create a more carbon neutral mix.

Concrete Recycling

As further examples of how concrete can be environmentally friendly in the form of a recycled material, visit the following link to learn the five step process for concrete recycling and ways reclaimed concrete is used for such things as underpass abutments, erosion control structures and pipe bedding. 

---

BioInnovation Center

The BioInnovation Center was the first laboratory building in Louisiana to achieve LEED Gold certification as a result of various sustainable features. The sustainable design features include:

• An outdoor water feature that also serves as a basin to capture rainwater and AC condensation which provides water to all the building’s landscaping

• Careful design which allows for more windows while reducing the solar gain of the facade

• Seventy five percent of the building facade provides daylight to illuminate the facility resulting in less energy usage during the day

• Building facade includes glaze that provides solar controls to assist with building temperature

---

Precast concrete building products are sustainable, versatile and durable. Regardless of whether the goal is LEED certification, or simply a building that is going to perform well for decades with minimal maintenance and excellent life cycle costs, precast concrete is a top performer that continues to outshine its competitors in nearly every environmental category over the long haul. Do it right the first time...this is HOW PRECAST BUILDS.