OLDCASTLE® RESIDENTIAL BUILDING SYSTEM

EQUUS DESIGN GROUP

ARCHITECTS • PLANNERS For more information, visit us at building. properly design nor any contractor to properly construct any Precast, Inc. will be responsible for the failure of any designer to tained within, neither Equus Design Group, Inc. nor Oldcastle implied with the use of this manual and information con- Since no specific project nor overall engineering responsibility is ings and references. sign methods, modifications or misapplications of these draw- for techniques of application, correctness, interpretations, de- any specific design or structure, and disclaim any responsibility Precast, Inc. makes any representations as to their fitness for trative only and neither Equus Design Group, Inc. nor Oldcastle The drawings and other information contained herein are illus- and other local requirements. every project must be designed to meet local site conditions college residence halls and senior buildings; however, helpful as references for the design of multi-family residences, dential buildings. Use of the information in this manual will be terested in the use of precast concrete building systems for resi- signed to assist Owners, Architects, Engineers, and others in- This Oldcastle Residential Building System manual has been de- USE OF THIS MANUAL „ „ „ „ „ „ „ TABLE OF CONTENTS References & Resources Case Studies Sustainable Design Architectural & Structural Details System Oldcastle Residential Building Residential Planning Principles Introduction to Oldcastle Precast www .oldcastlesystems.com

OLDCASTLE RESIDENTIAL BUILDING SYSTEM

Equus Design Group ArchitecTs • Planners A Building System... From a Single Provider... Partnering with Clients... with Partnering residences. residences, college dormitories and senior From a Single Provider... application in residential markets - multi-family buildings. It is a system designed for wide the total design and construction of residential method for architects and owners to employ for than just a kit of precast concrete parts. It is The Oldcastle Residential Building System is more A Building System... THE OLDCASTLE RESIDENTIAL SYSTEM Precast Building Systems for the 21st Century keeping costs under control. coordination issues and less site mobilization, while the changes or adapt design with less risk, fewer and envelope allows owners and architects to make responsible for the entire building superstructure residential buildings. Having a single source pre-fabrication and erection services for whole in TOTAL BUILDING SYSTEMS by providing design, manufacturer in the United States. We specialize Systems is part of the largest precast concrete advice and support. Oldcastle Precast Building process providing expert engineering and technical throughout the design and building construction staff works closely with owners and architects Oldcastle uses a cooperative team methodology. Our process. assist architects and engineers during the design owners and contractors time and money, and to tives are able to offer creative methods save Through direct partnerships, Oldcastle representa- from the initial design to construction completion. from project inception and each step of the way Oldcastle works directly with Owners and Architects

OP.1 OLDCASTLE RESIDENTIAL BUILDING SYSTEM

Equus Design Group ArchitecTs • Planners buildings, and contemporary and traditional styles. units, skip-stop elevator buildings, terraced styles of living – standard unit layouts, loft style Furthermore, the system can be utilized for most rise buildings, and low-income to luxury units. types – low and row housing, mid-rise high- designed for a wide variety of multi-family housing The Oldcastle Residential Building System is Multi-Family Residences 1 the architectural context of various campuses. in appearancesystem can be customized to suit apartments, studio, and couples housing. The Residence Hall types - dormitories, suites, Building System is adaptable to a wide variety of students. Similarly, the Oldcastle Residential cultural and economic backgrounds of their needs of different age groups and diverse multi- Colleges and universities respond to the housing olg eiec al Senior Living Residences College Residence Halls 2 senior living lifestyles and designs. System is adaptable to meet the needs of most continuing care. The Oldcastle Residential Building facilities, and special needs for dementia communities for active lifestyles, independent living choices including long term care, assisted living, has been a surge in design of wide variety of the need for new care and housing options. There expectations for a high quality of life, is creating The increasing numbers of older people, with their 3

OP.2 OLDCASTLE RESIDENTIAL BUILDING SYSTEM

Equus Design Group ArchitecTs • Planners minimizes the budget for casting, transporting and efficient sizes and shapes for components, which early and precise design aid that ensures the most Working in concert with the precaster can provide Design while keeping costs to a minimum. fewer coordination issues and less site mobilization, to make changes or adapt the design with less risk, source responsibility allows the owner and architect and technical advice support. Having a single construction process providing expert engineering owner’s team throughout the design and building methodology Oldcastle works closely with the building system. Using a cooperative team Oldcastle is the single source supplier for total Single Source Supplier sign include the following: cast Concrete Building Systems for Residential De- The many benefits of using Oldcastle’s Total Pre- ance. design methods development, and quality assur- product innovation, new technology adaptation, producers, suppliers and professionals dedicated to Concrete Institute (PCI), a national organization of Oldcastle is a member of the Precast/Prestressed cess. architects ensuring a smooth building delivery pro- creates a partnership with owners, developers and tems. From design through occupancy, Oldcastle single source delivery of Total Precast Building Sys- tradition today as an industry leader in providing Oldcastle Building Systems Division carries on that tures. construct long lasting, durable buildings and struc- world’s best architects and engineers to design the modern day, concrete has been used by the From the early Egyptians to Roman Empire to Benefits of Total Precast Systems through completion. envelope from the beginning of design process with a fully coordinated building structure and erectors will facilitate the commissioning process of project managers, engineers, fabricators and Contractors can be assured that Oldcastle’s team With Oldcastle Building Systems, Owners and and comfort. perform properly at the highest levels of efficiency systems are designed, installed, and tested to construction, which ensures that the key building Commissioning is the process, from design through Commissioning flexibility. costs and aids design speed while retaining erecting pieces. Component repetition reduces form Oldcastle Residential Building System provides nu- puses, to the suburbs and rural towns, the From urban cities, to college and university cam- Multiple Uses work earlier. enclosed allowing the interior trades to begin their increases the speed at which building can be foundation work are complete. This greatly can quickly proceed once the permitting, site and conditions, the erection of concrete components components year-round in nearly all weather time. With the ability to fabricate and erect system, reducing the required design and detailing be quickly replicated using a precast panelized wall Residential Building System. The components can reduced by up to 33% when utilizing the Oldcastle A project’s design and construction time can be Speed

OP.3 OLDCASTLE RESIDENTIAL BUILDING SYSTEM

Equus Design Group ArchitecTs • Planners Oldcastle Precast Systems are manufactured year- craftsmanship, on-time delivery and quick erection. or exceed ASTM and ACI standards, ensuring quality manufactured in PCI-certified facilities, and meet All Oldcastle Precast Building Systems products are High Quality Control enclosed buildings. There are two key factors: mate speed of both production and erection fully System of total precast concrete ensures the ulti- capital costs. The Oldcastle Residential Building duces other economic benefits that lead to reduced nancing costs, results in earlier cash flows, and pro- Faster construction completion reduces interim fi- Lower Capital Costs responsive to owner’s and designer’s needs. vocabulary of architectural expression that is fully Oldcastle precast concrete panels provide a large styles that fit almost any vision imaginable; and, tems are adaptable to a wide variety of building environment. Oldcastle Residential Building Sys- pride and that fits well into the built natural chitecture that invoke a sense of ownership and Residential buildings should feature stimulating ar- Stimulating Architecture ries, and senior living facilities. dential housing, college residence halls, dormito- merous building types and uses. Multi-family resi- time. earlier, thereby reducing overall construction riod enabling the interior trades to begin work tire building can be erected in a short time pe- As soon as the foundation is complete, en- Speed of Erection work is underway. weather controlled plant conditions while site exterior envelope can be constructed under the components of building structure and Owners and constructors can be confident that Plant Quality Control Concrete Institute (PCI). guidelines set forth by the Precast/Prestressed round in controlled environments under strict quality resources and has sustainable properties. sound material which is produced from sustainable performance precast concrete, an environmentally Oldcastle Residential Building Systems use high Environmental Impact Green Design • • • • Concrete is produced from some of earth’s And, after its original purpose has been served, the environment. concrete can be crushed and recycled back into swings. ergy year-round by reducing temperature gravel most abundant natural materials - sand and crete is quite small. The thermal mass of the concrete saves en- The production energy consumption of con- tion, and reduces heating cooling bills. duces HVAC loads, lowers overall energy consump- HVACsmaller-capacity systems which in turn re- temperature fluctuations, the ability to install more even ambient temperatures, resulting in less heat. Concrete provides thermal efficiency with ent thermal mass – the ability to absorb and retain because they take advantage of concrete’s inher- lope for controlling heat and cooling loss gain crete building systems are the best enve- life in residential buildings. Oldcastle’s precast con- Thermal comfort is a key attribute of the quality Enhanced Energy Performance mind that results from the certain knowledge Precast concrete offers the building owner peace of the easiest to maintain in building industry. perstructures and exterior envelopes that are among Oldcastle Building Systems feature all-concrete su- Durability and Maintenance

OP.4 OLDCASTLE RESIDENTIAL BUILDING SYSTEM

Equus Design Group ArchitecTs • Planners for their families and possessions. tenants with a strong sense of safety and security earthquakes. A concrete building provides its protection from hurricanes, tornadoes and required. Precast concrete also provides superior ratings, from unrated to two hours and more as System products are available in a variety of fire applying fireproofing material. Oldcastle Building or the messy, costly and time consuming work of resistance, eliminating the need for additional design precast concrete structure has built-in passive fire integrity even when subjected to extreme heat. A smoke or fumes, and maintains its structural Concrete does not burn, give off lethal Precast concrete is inherently noncombustible. Safety preserve their original look. sistance that require little or no maintenance to term durability, strength and inherent weather re- the building’s structure and exterior walls have long- 1 landings are placed, providing workers simple, safe safety. As work progresses, precast stairs and resulting in improved logistics and enhanced worker fabricated off-site, there is minimal site disturbance, scheduling. Since precast concrete components are subcontractor, resulting in efficient erection and for the entire building superstructure, there is one With Oldcastle as the single source responsibility Clean Site free interior spaces for flexible floor plan layouts. precast plank also offers the advantage of column- tection systems. With clear spans of up to 50 feet, ible layouts of mechanical, electrical and fire pro- while providing unobstructed ceiling cavities for flex- all building height. This saves materials and cost, the floor-to-floor height thereby lowering over- The shallow depth of precast floor plank reduces Floor-to-Floor Height and growth of hazardous mold mildew. few joints, reducing concerns about the formation precast concrete panels have low permeability and not "off-gas" unhealthy by-products. Furthermore, from natural, inorganic, non-toxic materials that do The Oldcastle Residential Building System is made that do not produce unhealthy gases. tion, comfortable climate, and the use of materials consist of a living environment with proper ventila- healthy environment. Healthy buildings generally Air quality is the most important attribute of a Improved Health environment. and ceilings, producing a quiet peaceful home terior walls, adjacent living units and interior floors for reducing unwanted noises from penetrating ex- precast concrete make it the best building product tical isolation and vibration attenuation qualities of ority in any comfortable living condition. The acous- Acoustical comfort from extraneous noises is a pri- Acoustics activities. adjacent businesses can maintain near-normal existing campuses and in dense urban areas, where provide a clean site is particularly important on and easy access to the building. The ability to erecting pieces. minimizes the budget for casting, transporting and efficient sizes and shapes for components, which and precise design aid that ensures the most team early in the design, Oldcastle can provide early completion. By working closely with the design owner from design concept through building Oldcastle believes in creating a partnership with the Partnering 2

OP.5 OLDCASTLE RESIDENTIAL BUILDING SYSTEM

Equus Design Group ArchitecTs • Planners PLANNING PRINCIPLES RESIDENTIAL

OLDCASTLE RESIDENTIAL BUILDING SYSTEM

Equus Design Group ArchitecTs • Planners P 1 Mixed-Use RP.13 Senior Residences Residence Halls RP.10 Multi-Family Residential RP.7 Forms in Section RP.4 Residential Forms RP.3 Low, Mid & High Rise RP.2 RP.1 PLANNING PRINCIPLES RESIDENTIAL

RP.0 OLDCASTLE RESIDENTIAL BUILDING SYSTEM

Equus Design Group ArchitecTs • Planners types include rowhouses, townhouses and studios. quiet urban streets, often with no elevator. Building typically found in residential neighborhoods and Low-rise buildings, from 1 to 3 stories high, are Row/Low-Rise building in suburban settings. The mid-rise is typically a low, broad, horizontal are the most common style of multi-family housing. Mid-rise buildings, 4 to 8 stories tall with elevators, i-ieHigh-Rise Mid-Rise the lower levels. are mixed-use occupancies with parking or retail at where land and parking are a premium. Often they and narrow, located in downtown, urban settings The high-rise, 9 stories and higher, is typically tall

RP.1 OLDCASTLE RESIDENTIAL BUILDING SYSTEM

Equus Design Group ArchitecTs • Planners NLSDCUTADCOSCR CENTRAL CORE CROSS CORE ENCLOSED COURTYARD PNCUTADRWGLEYPARALLEL FORMS GALLERY ROW OPEN COURTYARD TPE LNFA AAECEELTOSPOETOSINSERTIONS PROJECTIONS CRENELLATIONS FLAT FACADE STEPPED PLAN ONROFE LINEAR OFFSET CORNER with nearly limitless creative opportunities. building system provides the owner and architect The array of form possibilities with a total precast forms similar to those illustrated in this section. adaptable to a wide variety of orthogonal or planar The Oldcastle Residential Building System is construction type. analysis, and determined the appropriate desired relationships, performed a site and zoning have determined the program components and usually determined after the Owner and Architect recognizable forms. The form of the building(s) is Most residential buildings are organized in common RESIDENTIAL FORMS COLLECTED FORMS

RP.2 OLDCASTLE RESIDENTIAL BUILDING SYSTEM

Equus Design Group ArchitecTs • Planners GALLERY COURTYARD FORM W/ PARKING STEPPED LOW-RISE MID-RISE PARKING BELOW SKIP-STOP HIGH-RISE Advantages of skip-stop include: connects the floors of unit. Unit entry is from a corridor and an internal stair or fourth floor. The units are typically two stories. Skip-stop with limited width or particularly desirable views. one side of the building and is generally for sites Advantages of stepped include: typically formed by the top of unit below. where the units open to an outdoor terrace space The The single-loaded views and sunlight. building to the units maximize loaded corridor gives the exterior walls of corridor types serviced by elevators. The double- double or single loaded buildings are typically Mid-rise or between units. as row-houses, with interior stair circulation within Low rise FORMS IN SECTION urban locations. desirability, reduce land acquisition, and help in tight Parking • • • • • • ability to create parking or other non-residential ability to comply with zoning restricting building improved views and privacy less underutilized corridor space space ability to create two-story high loft type potential for cross-ventilation with views and stepped uses at inner levels where the footprint is larger lines heights at street or property sun exposure on two sides of the building (4-8 stories) and below the living space can increase housing (1-3 stories) is often designed plans locate a corridor on every second , or terraced, configurations are those gallery corridor places units on High-rise (9+ stories)

RP.3 OLDCASTLE RESIDENTIAL BUILDING SYSTEM

Equus Design Group ArchitecTs • Planners RESIDENTIAL MULTI-FAMILY townhouse. Parking is typically on grade or at the street outside exposures; and shared common walls with adjacent units. access to units or groups of units; both front and rear essential characteristics of the townhouse are direct street common form of row house. Typically 2-4 stories tall, the Row or Low-Rise housing. end of the corridor. to the units. Egress stairs are typically located at each of the building serving a double- or single-loaded corridor access that is often placed at approximately the mid-point portion of a city block. The mid-rise requires elevator in width or length than height, often covering a large 8 stories height range. The buildings are generally broader Mid-Rise professional offices, and, often, below-grade parking. housing projects offer other mixed-uses such as retail, number of units. An increasing high-rise stairs and other vertical elements that serve a limited street level lobby leading to a central core with elevators, Typical high-rise building configurations include a common wise be covered with lower scale housing. preservation of significant open space that might other- high-rise configuration offers excellent views or allows the dinances. However, it is also built in areas where the where high-density housing is allowed by local zoning or- High-Rise is defined by its scale. types possible. The fundamental character of the housing accommodate the widest range of multi-family housing The Oldcastle Residential Building System is designed to housing, as defined in this Manual, is the 4 to housing is generally found in urban settings, The townhouse is a very

RP.4 OLDCASTLE RESIDENTIAL BUILDING SYSTEM

Equus Design Group ArchitecTs • Planners higher. systems for buildings up to 18 stories and total precast structuralcapable of providing Oldcastle Residential Building Systems are TYPICAL SECTION view potential, for narrow lots, or to back-up to other buildings or uses. The The multi-family housing. It can be used for low-, mid-, or high-rise buildings. single loaded corridor, or “gallery”, is generally used to maximize best double-loaded corridor is the most efficient form of circulation in central core with elevators, stairs and other buiding services. Multi-family housing in high-rise buildings typically has a DOUBLE-LOADED CORRIDOR LAYOUT SINGLE-LOADED CORRIDOR LAYOUT CENTRAL CORE LAYOUTS

RP.5 OLDCASTLE RESIDENTIAL BUILDING SYSTEM

Equus Design Group ArchitecTs • Planners building material and cost. overall building height and the elimination of excess as steel frame. The result is a reduction in the to-floor height over other structural systems such over 50 feet, can greatly reduce a building’s floor- Precast concrete plank, with the ability to free span Typical Section Typical Row House Typical Multi-Family Unit Layouts BAY PROJECTION AEET1 BASEMENT TDO1B R3 BR 2 BR 1 BR STUDIO ST LVL2 LEVEL BALCONY ND LVL3 LEVEL RD are normally placed along the interior corridor wall. laundry and closets that do not require exterior light Service areas such as the kitchen, bathrooms, requiring these rooms to be along an exterior wall. bedrooms having direct access to outside light, thus normally have units with the main living areas and building layout. Buildings with long corridors Unit layouts are typically dependent on the overall LEVEL maintenance. residence that requires little or no saving, environmentally friendly end result is a quiet, energy and rear with precast panels the limitless. By enclosing the front the floor layouts are virtually and, with the use of precast plank, deadening precast concrete panels compartmentalized with sound System. Each unit can be Oldcastle Residential Building ideal building types for the Row houses and townhouses are

RP.6 OLDCASTLE RESIDENTIAL BUILDING SYSTEM

Equus Design Group ArchitecTs • Planners to suit their specific requirements. imaginations of the architect and owner to explore ideas building and living unit configurations, leaving only the This section of the manual illustrates various types of are providing them to attract the best students and faculty. characteristics; and an increasing number of institutions and Dormitories, Suites, Studios, Apartments, Couples universities to respond with appropriate housing types. student populations places demands on colleges and rooms with common shower areas. The diverse nature of recent years to more than the single or double occupancy At the same time, style of living units has evolved in facings to complement the most demanding conditions. includes variations on materials such as brick and other materials. Oldcastle’s system of precast components Often the need is for buildings with specific styles and generally a crucial factor in the design of residence halls. Fitting within the architectural character of campuses is Halls secure, energy efficient, and low maintenance The Oldcastle Residential Building System provides safe, RESIDENCE HALLS Faculty and Dormitories housing types each have different for colleges and universities. Residence ,

RP.7 OLDCASTLE RESIDENTIAL BUILDING SYSTEM

Equus Design Group ArchitecTs • Planners DOUBLE LOADED CORRIDOR ETA OECORNER CORE CENTRAL CORE SUITES IN DOUBLE-LOADED CORRIDOR CENTRAL CORE WITH maintenance partitions, greatly eliminates the need for some interior drywall and a trowel finish, ready for painting; this panels can be provided with a smooth form finish Corridor and living unit walls made of concrete central corridor. rooms to suites and apartment layouts along a Living units range from single or double occupancy rooms, study areas, kitchenettes and dining areas. bathrooms and showers as well conference functions with stairs, elevator, common parlor, residence halls often include centralized core Common floor plan arrangements for college BUILDING LAYOUTS RESIDENCE HALL issues. reducing

room

damage and

RP.8 OLDCASTLE RESIDENTIAL BUILDING SYSTEM

Equus Design Group ArchitecTs • Planners IN APARTMENT STYLE LAYOUT DOUBLE OCCUPANCY ROOMS DOUBLE OCCUPANCY ROOMS IN SUITE STYLE LAYOUT OCCUPANCY SINGLE OCCUPANCY DOUBLE SINGLE AND DOUBLE OCCUPANCY ROOMS IN APARTMENT STYLE LAYOUT IN APARTMENT STYLE LAYOUT SINGLE OCCUPANCY ROOMS OCCUPANCY DOUBLE bathrooms. with the addition of a kitchen and possibly private Apartment style housing is similar to suite undergraduate housing, do not have kitchens. self-contained private living areas, and like standard a shared living area and bathrooms. Suites are occupancy sleeping rooms, typically two to six, with Suite housing combines multiple single or double sharing common toilet and bathrooms. rooms arranged along a common corridor and consists of single or double occupancy sleeping Housing for younger undergraduates usually people in a more normal residential environment. students seeking to live with a specific group of appeal to older undergraduate and graduate students, while suites and apartment style units double-occupancy rooms for undergraduate administrators. Modern trends are for single and vary depending upon the philosophy of college The types of living arrangements in residence halls UNIT LAYOUTS RESIDENCE HALL

RP.9 OLDCASTLE RESIDENTIAL BUILDING SYSTEM

Equus Design Group ArchitecTs • Planners Rehabilitation and Nursing Homes. and care such as Alzheimer’s Care, Hospice Facilities for residents needing a high degree of services Long Term Care Residence care residence. needing the high level of care required in a long-term Housing for individuals unable to live on their own but not Assisted Living Residence of assisted living and long-term care residents. living to more focused and specialized health care needs care for a wide variety of needs ranging from independent CCRC’s are a model of living that provides services and Continuing Care Retirement Communities housing for people with limited care needs. Generally for the active over-55 age population, this is Independent Residential Apartments following: of providing housing and service needs to the widest range The Oldcastle Residential Building System is capable of care needs of this highly diverse group society. is faced with the challenge of meeting housing and The housing industry, in both the private and public sectors, rapidly growing population segment in the United States. The baby-boom generation of over-65 seniors is the most SENIOR RESIDENCES Senior Residence Building Types , including the

RP.10 OLDCASTLE RESIDENTIAL BUILDING SYSTEM

Equus Design Group ArchitecTs • Planners CENTRAL COURTYARD DOUBLE WINGS health care, and access to social activities. support services such as dining, housekeeping, housing for seniors requiring a full compliment of Continuing Care Retirement Communities require a high level of health care support. unable to live safely on their own, but who do not the residents. Typically they are for those who support services based on the changing needs of Assisted Living Residences age, with little to no health care support. within a communityfor seniors to live of others their Independent Living Residences requirement of the residents. and architects to meet the lifestyle health care Each one is programmed and designed by owners to assisted living and continuing care communities. seniors. They can range from independent living There are many options available lifestyle for common layouts are shown here. and owner architect preferences. Some configuration, lifestyle and program requirements, on a multitude of factors – site size and Building layouts of senior residences vary depending BUILDING LAYOUTS SENIOR RESIDENCE DOUBLE-LOADED CORRIDOR provide varying provide a place offer

RP.11 OLDCASTLE RESIDENTIAL BUILDING SYSTEM

Equus Design Group ArchitecTs • Planners LARGE 1 BR APARTMENT SLEEPER 2 BR SUITE STUDIO MULTI-BEDROOM SUITE 2 BR APARTMENT SMALL 1 BR effective solutions for each condition. and planning phases of the project to identify cost owners and architects in the early programming superstructure. Oldcastle representatives can assist building layout and characteristics of the appropriate considerably in the planning and design of and design requirements in a project helps Reaching an understanding of the living unit mix population. arrangements to suit the needs of a diverse senior Facilities, will have a wide mix of living unit Care Retirement Communities and Assisted Living Often the development, particularly in Continuing units that are commonly used in senior residences. This page shows several of the plan layouts for living and activities in the building. complemented with an array of beneficial services units, or shared suite arrangements, that are Alzheimer’s, may be better served with smaller changing conditions such as dementia or hand, some seniors, particularly those with life bedrooms, and adequate storage. On the other – full kitchens, large furnishable living rooms and living arrangement that reflects their independence independent lifestyles generally seek the type of of the individuals. Seniors still living active, depending on the health, well-being and lifestyle Senior residence living unit designs vary greatly making process. individual living unit is at the heart of their decision- specific market targets. The design of each architects, create programs and designs to suit Developers of senior living facilities, and their UNIT LAYOUTS SENIOR RESIDENCE

RP.12 OLDCASTLE RESIDENTIAL BUILDING SYSTEM

Equus Design Group ArchitecTs • Planners both the superstructure and building envelope. to maximize the potential for cost-effective solutions the program and design parameters early in the process Oldcastle representative to gain a clear understanding of accommodate varying conditions. It is important for the designed to create superstructure solutions that The Oldcastle Residential Building System is specifically uses could be combined into a single building. offices, and retail space. Nevertheless, all of these different housing, hotel rooms and conference areas, professional and the space it needs - is different for multi-family For example, the module of a parking garage - car understanding of a design module that can suit each use. is important at the outset of design to gain an Where a mix of different uses is required in the building, it a single building. of providing more than one use in a development, often Owners and architects are often faced with the challenge MIXED-USE

RP.13 OLDCASTLE RESIDENTIAL BUILDING SYSTEM

Equus Design Group ArchitecTs • Planners OLDCASTLE RESIDENTIAL BUILDING SYSTEM

OLDCASTLE RESIDENTIAL BUILDING SYSTEM

Equus Design Group ArchitecTs • Planners S1 Other Trim Materials BS.19 Brick Finishes BS.18 Embedded Brick BS.15 Formliner Finishes BS.14 Concrete Finishes BS.13 Facade Treatment Options BS.11 Elevators BS.10 Stairs BS.9 Balconies BS.8 Floor and Roof Plank BS.7 Wall Panels BS.5 Bearing Wall System BS.4 Cross Wall System BS.3 Precast System Components BS.2 Architectural Principles of BS.1 BUILDING SYSTEM RESIDENTIAL OLDCASTLE Concrete Design

BS.0 OLDCASTLE RESIDENTIAL BUILDING SYSTEM

Equus Design Group ArchitecTs • Planners constructed. which building elements are designed and and Roman architecture is the What is particularly striking about Egyptian, Greek enduring structures of all time. having created some of the most beautiful and ancient forums to today’s tourism; and commodity great Pantheon, were constructed of concrete, creating Many of their buildings, including the beautiful The ancient Romans were no strangers to concrete. senses attributes of design, lifting the spirit and stimulating Delight and value Commodity Firmness Commodity, and Delight. fundamental principles of architecture – taught what he considered to be the three the author of classic textbook The First Century BC Roman Architect Vitruvius, design that date back to ancient times. Architects are taught time-honored principles of OF PRECAST DESIGN PRINCIPLES ARCHITECTURAL refers to the aesthetically and visually appealing firmness refers to structural integrity and durability refers to the production of items use of usefulness that has lasted from the lasting over 2000 years, Pantheon orderly 1 De architectura manner in Firmness, delight orderly system of music to create timeless classics. Parker, Hank Williams and Chuck Berry all used the same J.S. Bach, Amadeus Mozart, Thelonius Monk, Charlie a total of 7 notes - musical order. Most songs that we know consist of There are strong similarities in architectural and “I call architecture frozen music.” Architecture and Music satisfy their most rigorous principles of design. an orderly array of building components that can create a perfect opportunity for architects to find buildings into architecture. Precast components order to building design is how architects make Creating clear, simple, well-proportioned structural “Design is form-making in order” Order in Architecture notes we learned as children. Yet it is all out of a very simple, orderly system differing of thousands different pieces music with With these 7 notes we are able to create hundreds Note the timeless and orderly design of piano keyboard rhythms Salk Institute by Louis Kahn , Do, Re, Mi, Fa, So, La, and Ti harmonies – Louis Kahn Johann Wolfgang Goethe , and compositions 2 3 . . also elegant design. resulting in not only economical construction, but create total precast order in the design of buildings, Oldcastle representatives can assist architects to of the world’s great architecture has been achieved. rhythmical and harmonious building elements, some And so it is with architecture. Out of a few “Less is more.” Order in Precast Design orderly design is achieved at the Melrose II housing development in Using a few identical precast components steady rhythm and Detail from the Hollyhock House by FrankDetail from the Hollyhock House by Wright Lloyd Mies van der Rohe New York City. 5 4

BS.1 OLDCASTLE RESIDENTIAL BUILDING SYSTEM

Equus Design Group ArchitecTs • Planners ROOF PLANKS FLOOR AND LANDINGS STAIRS AND BEAMS COLUMNS FINISHES FORM LINER FACING REAL BRICK CORNICES DECORATIVE „ „ „ „ „ NON-INSULATED LOAD BEARING PANELS EXTERIOR INSULATED AND SYSTEM COMPONENTS OLDCASTLE PRECAST manual. of residential building types and uses illustrated in this components is designed to accommodate the wide range and the entire superstructure, Oldcastle System of finishes, to floor and roof structures, stairs shafts, residential buildings. From exterior walls with architectural Oldcastle provides total precast concrete solutions for „ „ „ „ „ EXTERIOR NON-LOAD BEARING PANELS „ „ „ „ „ PANELS AND SHAFTS INTERIOR LOAD BEARING „ „ „ „ „ AND SHAFTS BEARING PARTITIONS INTERIOR NON-LOAD SLABS BALCONY

BS.2 OLDCASTLE RESIDENTIAL BUILDING SYSTEM

Equus Design Group ArchitecTs • Planners „ „ „ COLUMNS „ „ BEAMS & „ „ „ CROSS WALL „ „ LOAD BEARING „ „ „ „ „ FLOOR PLANK „ „ „ „ „ BALCONY SLAB „ „ „ EXTERIOR WALL „ „ NON-LOAD BEARING „ „ „ „ „ ROOF PLANK system. superstructure, providing a total precast concrete building Non-load bearing exterior panels can enclose the planks. Columns and beams are used at parking levels. of load-bearing interior precast panels and floor roof The Oldcastle Residential Cross Wall System is comprised CROSS WALL SYSTEM SECTION Cross Wall Advantages: • • • • between units sound-deadening precast walls Creates the opportunity for partitions of non-load bearing exterior Allows for a high percentage of bays and balconies Lends itself well to the addition levels buildings with parking at lower Ideally suited for residential „ „ „ „ „ „ „ „ „ „ „ „ „ „ „ „ „ „ „ „ „ „ „ „ „ COLUMNS BEAMS & EXTERIOR WALL NON-LOAD BEARING CROSS WALL LOAD BEARING FLOOR PLANK ROOF PLANK

BS.3 OLDCASTLE RESIDENTIAL BUILDING SYSTEM

Equus Design Group ArchitecTs • Planners „ „ „ INTERIOR WALL „ „ LOAD BEARING „ „ „ „ „ FLOOR PLANK „ „ „ EXTERIOR WALL „ „ LOAD BEARING „ „ „ „ „ ROOF PLANK building system. floor and roof plank, providing a total precast concrete of load bearing interior and exterior precast panels with The Oldcastle Residential Bearing Wall System is comprised BEARING WALL SYSTEM SECTION Bearing Wall Advantages: • • • • • structure is being erected Building is enclosed as solution Least expensive total precast precast wall at the corridor Creates a sound-deadening floor plan layouts Creates flexible options for building plans Maximizes the open areas of „ „ „ „ „ „ „ „ „ „ „ „ „ „ „ „ „ „ „ „ EXTERIOR WALL LOAD BEARING INTERIOR WALL LOAD BEARING FLOOR PLANK ROOF PLANK

BS.4 OLDCASTLE RESIDENTIAL BUILDING SYSTEM

Equus Design Group ArchitecTs • Planners MAX 40’ TNADPNLINSULATED PANEL STANDARD PANEL VERTICAL 12’ MAX inches. conditions usually require 8- inches, whereas load-bearing require no more than 6- bearing conditions typically use and function. Non-load 8-inches thick, depending on Standard wall panels are 6 to MAX 12’ SPECIAL SHAPES HORIZONTAL 40’ MAX and load-bearing conditions. used in both non-load bearing Insulated wall panels can be inch concrete interior. of rigid insulation, and 2-8 concrete exterior, 2-3 inches of three wythes; a 2-3 inch Insulated wall panels consist 1 at the job site. then lifted by cranes and stored until delivery and erection placed, the concrete is poured and cured. The panels are perimeter. After reinforcement and lifting devices are the forming bed, and rails are placed to form the panel Window and door openings are created by “blockouts” on facing options are available. architectural effect, various formliner finishes or masonry controlled factory conditions. Depending on the desired Typically, precast panels are cast on flat forming beds within for total precast solutions residential buildings. architectural finish panels, the Oldcastle system is designed structural panels to exterior, insulated, brick-embedded configurations and finishes. From interior load-bearing panels are available in a wide variety of types, Within the Oldcastle system of components, precast wall WALL PANELS

BS.5 OLDCASTLE RESIDENTIAL BUILDING SYSTEM

Equus Design Group ArchitecTs • Planners precast wall panels. design by the use of large and repetitively designed Tremendous economies can be achieved in building constructed building elements that large are rare. 40 feet long. Outside the precast industry, factory- the size of precast panels to about 12 feet high and Shipping and handling constraints generally limit Panel Sizes ways. elegant architecture, and to do so in cost-effective precast wall panels to create orderly, rhythmic, and There are a number of design opportunities with CONSIDERATIONS WALL PANEL casting bed. simply by moving a perimeter forming rail on the form can be used to create different sized panels, architect’s intent. In some cases, however, the same panels to satisfyan orderly system of wall the Oldcastle’s design support representatives to create the owner and architect should work closely with castings from each form. Early in the design process form changes, and to maximize the number of wall panels is to minimize the number of forms and A key consideration to cost-effective production of Repetition Whole Panel Cast Cast Left Center Cast Right Cast representative can discuss. there are exceptions that the Oldcastle of 8 inches from the edge panel; however, during shipping and handling, generally a minimum structural integrity of the panel is not compromised important to place openings in locations where the using standard window and door sizes. It is the desired architectural effect of the designer, often Opening sizes in panels are usually determined by Opening Sizes and Locations the planes of panels. are recommended to alleviate alignment issues in design to meet other panels, ½ - ¾ inch chamfers inch is recommended; however, where panels are for chipping during handling. A minimum of 1/8 a weakened and uneven edge and greater potential due to large aggregate interference. The result is aggregate collects along the edge, or voids occur finished edge. Without a chamfer, only fine edges of concrete panels to produce a clean, smooth Chamfers are recommended at the exposed-to-view Chamfers HMESDRAFT CHAMFERS recommended. the form cleanly. A minimum draft of 8 degrees is draft allows the completed panel to be released from that create the openings in concrete panels. The A “draft” is a slight angle created around the forms Drafts desirable architectural effects. curvatures can be manufactured to achieve triangular pediments, arch openings, and even produce, however, pieces such as specialty Rectilinear shapes are the most economical to Panel Shapes provided in this Manual. Detailed descriptions of available finishes are formliner finishes, and embedded masonry. Residential Building System – form finishes, A wide array of finishes is available in the Oldcastle Panel Finishes

BS.6 OLDCASTLE RESIDENTIAL BUILDING SYSTEM

Equus Design Group ArchitecTs • Planners structural support such as a steel header or beam. etc.) are generally introducing a created by The largest openings (mechanical shafts, stairs, a hand-held saw or a walk-behind concrete saw. Openings larger than ten inches are usually cut with walls are thinnest at top and bottom. at the center of core is easiest because cut with diamond bit core drilling equipment. Drilling drilling equipment. Larger round holes are usually with readily available carbide tips using hand-held Round holes up to one-inch diameter can be drilled of plank requires the approval of Oldcastle. be provided by Oldcastle. Cutting through strands General Contractor, whereas larger openings can Round holes are generally the responsibility of systems as well other equipment and functions. penetrations of vertical mechanical and electrical Hollow core plank floors and roofs typically require PENETRATIONS Set 200 portland cement based underlayment. concrete leveling material such as Oldcastle’s Level- 2 inch, 4000-psi, steel mesh reinforced), or a covered with a structural concrete topping (generally (carpet, tile, vinyl flooring, etc.), the plank can be For floors, prior to receiving other finish materials recommendations for application. taken to follow the manufacturer’s properties and an attractive finish. Care must be such as USG Imperial QT or equal, provides acoustic application of a medium to heavy textured material used in applications such as hotels rooms. The to provide a durable, low maintenance surface, often For ceilings, the underside of plank can be finished FINISHES finishes. of a project in order to determine appropriate floor understanding of the effect camber during design Design professionals should obtain a clear adjacent to each other will have camber differences. with dissimilar lengths, strand patterns or openings strands; and it is used to resist design loads. Planks the plank created by the forces of prestressed concrete products. It is the upward deflection in Camber is inherent in all prestressed precast CAMBER are as follows: tions, plank thicknesses required for various spans As a rule of thumb, under normal loading condi- longer spans and higher working load capacities. strand gives the plank tensile properties for plank, and the depth of any concrete topping. The number and size of steel strand (or wires) in the cable Codes), the width and depth of plank, required loading capacity (generally set by appli- The length of precast plank spans is determined by SPANS 16” PLANK : 40’ - 50’ SPAN 12” PLANK : 35’ - 40’ SPAN 10” PLANK : 33’ - 35’ SPAN 8” PLANK : 28’ - 30’ SPAN runs of mechanical or electrical systems. and cost and, at the same time, may be used for The planks have continuous voids to reduce weight rior acoustic and fire resistance properties. plank offers high load-bearing capacity with supe- sonry and/or steel structural systems, hollow core system solution or, independently, with other ma- Whether used as part of a total precast building used concrete product in the building industry. tural floor and roof applications, is the most widely Precast, prestressed hollow core plank, for struc- SYSTEMS FLOOR & ROOF

BS.7 OLDCASTLE RESIDENTIAL BUILDING SYSTEM

Equus Design Group ArchitecTs • Planners priate designs. age. Consult with Oldcastle engineers for appro- preferred method, enabling proper pitch and drain- and recessed applications. Wet cast slabs are the concrete balconies and bays in both cantilevered Oldcastle offers a variety of solutions for precast BALCONIES

BS.8 OLDCASTLE RESIDENTIAL BUILDING SYSTEM

Equus Design Group ArchitecTs • Planners the roof. roof slope less than 4 in 12 require stair access to Roof Access that a 4-inch diameter sphere can not pass through. and shall have balusters or ornamental patterns so measured vertically from the leading edge of tread Guardrails the stairs and return to a wall or guard. ends must project beyond the top and bottom of tread nosing. Handrails must be continuous or the uniform in height, located 34”-38” above the stair no more than 4-1/2” on each side. They shall be and may project into the required stairway width Handrails of stairs has a rise greater than 12’-0”. intermediate points to ensure that no single flight required at the top and bottom of stairs than the width of stairway and are they serve Landings is: 2 x riser height + tread depth = 25 inches. common rule for comfortable proportioning of stairs The tread depth shall be 11” min. most shape. Risers shall be between 7” max. and 4” min. Risers and Treads stairways. shall not be less than 48” wide for enclosed exit Stairway Width with the latest national and local codes. stairways common building code requirements for The information contained here summarizes some is strictly controlled b egress systems of most buildings, Being an essential component in the circulation and CODE CONSIDERATIONS – the width of landings shall not be less – are required on both sides of stairs . However, designers must always verify – shall be no less than 42” high, – buildings over four stories with a – the minimum stairway width - shall be of uniform size and y building code regulations. stairw a y design egress as part of the Oldcastle Residential Building System. precast concrete components that can be provided Stairway walls, floors, landings and steps are all STAIRS

BS.9 OLDCASTLE RESIDENTIAL BUILDING SYSTEM

Equus Design Group ArchitecTs • Planners ELEVATOR SECTION ELEVATOR PLAN serve low- to mid- high-rise buildings. speeds and almost limitless rise allow electric elevators to either at the base or above hoistway. Medium to high cables and a counterweight. The electric motor is located sheave that raises and lowers the elevator cab by steel Electrical elevators rely on an electric motor and drive Electric Elevators during operation. require the least initial installation cost, but use more power buildings of up to approximately 60 feet. They generally hydraulic elevators are limited to low- and mid-rise to restrictions in the plunger length and lower speeds, to raise and lower the elevator cab using a plunger. Due “holeless”. Both use a pump near the base of hoistway Hydraulic elevator holed and systems come in two styles, Hydraulic Elevators and Electric elevators. The two most common elevator systems are Hydraulic is chosen. process to ensure that the most suitable elevator system consulted early in the design phase and during selection An elevator representative and code official should be Residential Building System. penthouse to complement and support the Oldcastle to meet the requirements of elevator hoistway and Oldcastle Precast has a complete line of concrete products and other factors. the number of occupants, floors, floor heights Proper sizing, quantity and type of elevator depends on room, cab and lobbies, is an integral and complex system. The elevator system, consisting of the hoistway, machine ELEVATORS

BS.10 OLDCASTLE RESIDENTIAL BUILDING SYSTEM

Equus Design Group ArchitecTs • Planners FACADE TREATMENT OPTIONS opportunites for owners and architects. Oldcastle creates an enormous range of design The variety of facade treatment options offered by can be cast directly onto the face of concrete panels. a traditional masonry appearance, thin brick veneer integrated into concrete forms. For owners seeking as large cornices and other features can be of a panel. Deep reveals and medallions, as well form liners can be added to increase visual interest Various textures such as simulated stone or masonry are available for selection. capacity. A variety of colors, textures and shapes combines architectural effects with structural Precast concrete is a moldable material which variety of design objectives. production and erection details, can achieve a wide and textures, combined with well-conceived components. The choice of appropriate aggregates façade treatment options for exterior building Oldcastle offers a range of colors, textures and other the fine and then coarse aggregate colors. are exposed, the panel color increasingly exhibits surface is progressively removed and aggregates the exposed concrete surface. As color influence on a smooth finish because it coats Cement light, shadow, texture and color. appearance is a function of the architect’s use of Surface texture influences color. The building’s the strong light and shadows of natural daylight. which the precast concrete will be used, such as under lighting conditions similar to those or nearby colors. Color selection should be made light, shadow, density, time and other surrounding Color and, consequently, color tone are affected by accentuates the natural beauty of aggregates. of exposure. Combining color with texture size of aggregates, finishing processes, and depth and texture by varying aggregate and matrix color, Design flexibility is possible in precast concrete color Colors and Textures (plus coloring agent) exerts the primary Fine aggregates example, will produce cleaner, brighter colors. aggregate alone. White portland cement, for obtained through combinations of cement and fine added to the matrix obtain colors that cannot be Pigments often preferable. depending on their source; and local sources are have inherent color and shading differences may be gray, white, buff or a mixture. All cements an effect on the general tone of the panel. Cement Nevertheless, the color of cement always has aggregate a matte finish. aggregates. Sandblasting, for example, will give the finishing processes change the appearance of medium or deep aggregate exposure profile. Some surface of the concrete is removed to obtain a Coarse aggregate profile to increase their exposure. add color tones when the surface is given a shallow of white and light buff colored concrete, can and pigmented admixtures often are have a major effect on the color colors become dominant as the

BS.11 OLDCASTLE RESIDENTIAL BUILDING SYSTEM

Equus Design Group ArchitecTs • Planners ease of masonry installation. the option of concrete-embedded dovetail slots for façades over precast panels, Oldcastle also offers For owners seeking conventional brick and/or stone consuming site construction of masonry products. or weep cavities, no efflorescence, and time- conventional masonry include: no flashing, lintels Advantages of brick-embedded concrete over brick patterns. to create corners, arches, soldier courses, and other color choices, as well various shapes and sizes molded textures, iron spot flashed bricks, numerous options including smooth, wire-cut, and sand- Owners and architects have a wide range of brick brick sizes. masonry production and are offered in standard bricks are manufactured by the nation’s leaders in brick is integrally cast into concrete panels. The and related building façade products whereby thin simple, cost-effective ways of producing wall panels For owners seeking brick finishes, Oldcastle offers Brick designs. and other geometric shapes, as well custom Patterns include masonry, sandblast, stone, rock, the owner and architect. patterns and finishes that best suit the needs of design and manufacturing to select concrete Oldcastle works with industry leaders in formliner process. available with the use of formliners in casting Numerous concrete textures and patterns are Formliners planning modules or structural bays. emphasize changes in texture, and highlight panel joints to express floor, ceiling or roof lines, Designers often use reveals in combination with in special cases the draft may be reduced to 1:12. a mold is one inch in eight inches (1:8), although preferred minimum draft for ease of stripping from stripping from the concrete form. Generally, the with a 45-60 degree bevel or “draft” for ease of Reveals typically measure 1/2 to 3/4 of an inch deep diagonally, and in a variety of sizes and shapes. Reveals can be placed vertically, horizontally, of the building. articulation helps designers to modulate the scale an expanse of precast concrete. The exterior offer a simple and cost-effective way to break up desired architectural effect. Used effectively, reveals A reveal is a groove in a panel face used to create Reveals coating manufacturer’s product data. and temperature conditions, as specified by the the proper thickness, and under weather For successful results, coatings must be applied at concrete and moisture. as they may chemically react with the alkaline alkyd or oil-based coatings should not be specified acrylics, epoxies, and polyurethanes. Generally, Coatings that work successfully on concrete include performance coatings to suit most conditions. can make specific recommendations for high- requirements of the owners and architects, Oldcastle Depending upon the visual effects and performance manufactured for exterior concrete application. collection of product coatings specifically The U.S. paint and coatings industry offers a diverse Architectural Coatings have grooved or dovetail-like slots. concrete, the backside of clay products should limitless. To develop the best adhesion to ornamental decoration. The design possibilities are or thin brick can be cast into the concrete to create Additionally, clay products such as tile, terra-cotta the desired design effect. however they can be large or small depending upon same depth and draft considerations of reveals, dimensional relief. Blockouts generally have the block-outs within the formwork to provide three- wide recesses can be created in the concrete using Similar to the techniques used for creating reveals, on concrete panels, Oldcastle offers solutions. ornamental decoration, or three-dimensional relief For owners and architects seeking to create Ornamental Decoration 1

BS.12 OLDCASTLE RESIDENTIAL BUILDING SYSTEM

Equus Design Group ArchitecTs • Planners 13 Photos courtesy of PCI satisfactorily matched. the desired colors and textures can be Samples should be required to ensure that matching by all precast concrete producers. photographic sample and obtain exact architect should not expect to select a or different techniques in various plants, the Additionally, due to different material sources samples must be expected. mix designs, some variations from these exactly on paper the true colors of precast conditions. Since it is impossible to reproduce textures seen will vary depending on local It is important to note that the colors and guide for initial selection of color and texture. blends. These samples serve only as a visual many of the available color and texture The images shown in this manual represent Note: effect desired. information on how to best obtain the visual throughout the development of the design for representative in the early design stages and architect should contact the local Oldcastle precast concrete colors and textures. The Oldcastle Precast offers a wide range of SAMPLE CONCRETE FINISHES 14 910 09 01 516 15 05 06 03 02 17 12 11 07 18 08 04

BS.13 OLDCASTLE RESIDENTIAL BUILDING SYSTEM

Equus Design Group ArchitecTs • Planners requested. more accurate literature and samples when Oldcastle representative will make available initial concept, not for actual selection. The The samples shown are only a visual guide for many of the textures and patterns available. The images shown in this manual represent pages. represented in the patterns shown on these manufacturers of formliners including those works directly with the nation’s premier in almost any style imaginable. Oldcastle the option to create custom formliner finishes and textures offered as standard, there is also effect. In addition to a vast array of patterns formliners to create almost any desired visual option to cast concrete in forms with specialty Oldcastle offers owners and architects the Formliners SAMPLE FORMLINER FINISHES Low Profile aor Stone and Rock Masonry

BS.14 OLDCASTLE RESIDENTIAL BUILDING SYSTEM

Equus Design Group ArchitecTs • Planners • • • • • NO FLASHING NO LINTELS NO WEEP JOINTS NO AIR SPACE NO MORTAR RUNNING BOND AKTWAEQATRBN OLC ODSOLDIER BOND ROWLOCK BOND QUARTER BOND BASKET WEAVE OESML SHAPES AND SIZES SAMPLE CORE • • • • ANCHORS NO DOVETAIL NO FREEZE/THAW NO EFFLORESCENCE NO WATERPROOFING LMS ODHL ODSTACKED BOND HALF BOND FLEMISH BOND COURSING OPTIONS 1 3 2 consuming site construction or masonry products. or weep cavities, no efflorescence and time- brick-embedded concrete include no flashing, lintels a multitude of coursing options. Advantages of shapes, colors and textures are offered, as well into concrete panels. A wide variety of sizes, Oldcastle offers thin brick which is integrally cast For owners and architects seeking brick finishes, EMBEDDED BRICK 4

BS.15 OLDCASTLE RESIDENTIAL BUILDING SYSTEM

Equus Design Group ArchitecTs • Planners visually pleasing façade. different patterns, and create a well-ordered, pattern. This will also help to align openings in the consider aligning the brick pattern with concrete rectilinear or modular (e.g. a stone pattern), D. When using a is not used at the edge of panels. This is particularly important when concrete banding panel to panel, both vertically and horizontally. C. brick coursing. and opening sizes to be any dimension, independent of Furthermore, banding joints, and other desirable architectural effects. Banding can be used to distinguish floor locations, panel along a panel edge against which the brick is set. Note: Banding involves creating a solid concrete face to of precast panels and openings. Banding can help B. Consider the use of panel widths, heights, and openings. A. Use considerations include: detailing of each project. Some the to be carefully considered during the design and panel openings, and brick tolerances need panel sizes and shapes, load-bearing conditions, embedding of brick in precast panels. Brick and There are several design considerations for the fit the module of brick. sizes or the need to build panels that only alleviate the costly need of cutting brick to odd Masonry coursing modular brick sizes allows for panel heights, widths formliner pattern concrete banding should be continuous from when determining at edges that is EMBEDDED BRICK PANEL CONSIDERATIONS Tolerances to be taken into consideration include: considered during the design. both precast panels and thin brick need to be I. Industry standard manufacturing is cut equally on either side of the opening. make sure the opening is located so that brick modular sizes. If a special size opening is required, although it is more costly than using standard edges of panels and panel openings can be achieved, H. If necessary, might require ordering custom size windows. Note: Creating opening sizes that fit the brick module G. modular pattern. should be placed symmetrically within the brick F. Precast recommended concrete jamb band width. window or door openings ¾ inch is the minimum E. When using concrete within the brick module. and jambs. Opening sizes should fit symmetrically well as for brick returns at window and door heads 6. Joint details 5. Load bearing conditions 4. Joint sizes 3. Brick coursing 2. Panel heights 1. Floor-to-floor heights Corner brick header and sill cutting brick can be used for panel ends as banding at jambs heights and lengths to special sizes at tolerances of of

BS.16 OLDCASTLE RESIDENTIAL BUILDING SYSTEM

Equus Design Group ArchitecTs • Planners to fully cover any flat brick surface. extender is required from the window manufacturer the cutting of bricks is a goal. At sills, sloping sill planning of window sizes is required if minimizing can be applied at jambs, sills and heads. Careful For an all-brick facade appearance, brick returns 23456 4 3 12 BRICK FRAME 3 1 5 ls rpordn ls rpordn flush or protruding flush or protruding flush or protruding EMBEDDED BRICK OPENINGS typically applied at the jambs. protruding from the brick facade. Brick returns are heads, concrete can be formed either flush with or For the traditional appearance of stone sills and BRICK AND CONCRETE FRAMES TYPICAL OPENING DETAILS 2 4 5 can be flush with the facade or protruding. the concrete, not brick coursing. The concrete frame of window sizes as the openings are determined by the amount of brick cutting and allows for flexibility concrete at the jambs, sill and head. This reduces The most cost-effective opening is formed with CONCRETE FRAME 2 4 6

BS.17 OLDCASTLE RESIDENTIAL BUILDING SYSTEM

Equus Design Group ArchitecTs • Planners and samples when requested. make available more accurate color literature selection. The Oldcastle representative will visual guide for initial concept, not actual site. The color samples shown here are only a be blended from numerous cartons on the job run to and within each run. Bricks should Thin brick may vary in size and shade from time. no efflorescence; and reduced construction include no flashing, lintels or weep cavities; Advantages of brick-embedded concrete minimum quantity orders. blends are available by custom order in such as light, dark, and vintage flash mixed are also available. Furthermore, flashed blends texture blends. Brick corners and edge caps represent many of the available color and available. The images shown in this manual brick, there is a wide array of brick options the nation’s premier manufacturers of thin option to integrally cast brick in concrete. From Oldcastle offers owners and architects the Thin Brick SAMPLE BRICK FINISHES

BS.18 OLDCASTLE RESIDENTIAL BUILDING SYSTEM

Equus Design Group ArchitecTs • Planners cotta, ceramics, masonry, EIFS, and fiberglass. trim materials such as composites, metal, wood, terra and design of its precast products with various exterior Oldcastle assists designers and owners in the coordination OTHER TRIM MATERIALS

BS.19 OLDCASTLE RESIDENTIAL BUILDING SYSTEM

Equus Design Group ArchitecTs • Planners STRUCTURAL DETAILS ARCHITECTURAL &

OLDCASTLE RESIDENTIAL BUILDING SYSTEM

Equus Design Group ArchitecTs • Planners 4 1 NON-INSULATED PANEL-TO-FOUNDATION DETAIL NON-INSULATED LOAD-BEARING PANEL DETAIL 5 2 INSULATED PANEL-TO-FOUNDATION DETAIL INSULATED LOAD-BEARING PANEL DETAIL ARCHITECTURAL DETAILS 3 building. properly design nor any contractor to construct Precast, Inc. will be responsible for the failure of any designer to tained within, neither Equus Design Group, Inc. nor Oldcastle implied with the use of this manual and information con- Since no specific project nor overall engineering responsibility is and references. sign methods, modifications or misapplications of these drawings for techniques of application, correctness, interpretations, de- any specific design or structure, and disclaim responsibility Precast, Inc. makes any representations as to their fitness for trative only and neither Equus Design Group, Inc. nor Oldcastle The drawings and other information contained herein are illus- USE OF THESE DETAILS BELOW-GRADE PARKING FOUNDATION DETAIL

AS.1 OLDCASTLE RESIDENTIAL BUILDING SYSTEM

Equus Design Group ArchitecTs • Planners 4 1 TYPICAL COPING DETAIL AT ROOF TYPICAL COPING DETAIL AT PARAPET 5 2 INSULATED PANEL WITH PARAPET DETAIL PRECAST PARAPET DETAIL ARCHITECTURAL DETAILS 6 3 INTERIOR PANEL-TO-FOUNDATION DETAIL INTERIOR PANEL-TO-PANEL DETAIL

AS.2 OLDCASTLE RESIDENTIAL BUILDING SYSTEM

Equus Design Group ArchitecTs • Planners 4 1 PRECAST CONCRETE BEAM SECTION MITERED CORNER JOINT DETAIL 5 2 WINDOW SILL DETAIL - NON-INSULATED PANEL BUTT CORNER JOINT DETAIL ARCHITECTURAL DETAILS 6 3 WINDOW SILL DETAIL - INSULATED PANEL BRICK CORNER JOINT DETAIL

AS.3 OLDCASTLE RESIDENTIAL BUILDING SYSTEM

Equus Design Group ArchitecTs • Planners 4 1 AT FOUNDATION EXTERIOR INSULATED WALL EXTERIOR INSULATED WALL PLANK END BEARING AT 2 5 EXTERIOR WALL AT FOUNDATION PLANK END BEARING AT EXTERIOR WALL STRUCTURAL DETAILS building. properly design nor any contractor to construct Precast, Inc. will be responsible for the failure of any designer to tained within, neither Equus Design Group, Inc. nor Oldcastle implied with the use of this manual and information con- Since no specific project nor overall engineering responsibility is ings and references. sign methods, modifications or misapplications of these draw- for techniques of application, correctness, interpretations, de- any specific design or structure, and disclaim responsibility Precast, Inc. makes any representations as to their fitness for trative only and neither Equus Design Group, Inc. nor Oldcastle The drawings and other information contained herein are illus- an Oldcastle representative for specific details each project. System details for various building conditions. Please consult These details represent a sampling of typical Oldcastle Building USE OF THESE DETAILS 3 PLANK SIDE CONNECTION AT EXTERIOR WALL

AS.4 OLDCASTLE RESIDENTIAL BUILDING SYSTEM

Equus Design Group ArchitecTs • Planners 4 1 PRECAST COLUMN AT FOOTING PRECAST CONCRETE BEAM SECTION 2 5 INTERIOR WALL AT FOOTING PLANK END BEARING AT INTERIOR WALL STRUCTURAL DETAILS 6 3 CORRIDORS AND LARGE OPENINGS SECTION ATBEARING AND PLANK PLANK END BEARING AT EXPANSION JOINT

AS.5 OLDCASTLE RESIDENTIAL BUILDING SYSTEM

Equus Design Group ArchitecTs • Planners 4 1 ROOF PLANK BEARING AT INTERIOR WALL ROOF PLANK BEARING AT EXTERIOR WALL 5 2 WITH HIDDEN CONNECTION WALL PANEL BUTT JOINT AT CORNER WALLPANELS INSIDE WELD PLATE CONNECTION (PLAN VIEW) (PLAN VIEW) STRUCTURAL DETAILS 6 3 INTERIOR WALL PANEL JOINT AT CORNER WALLPANELS OUTSIDE WELD PLATE CONNECTION (PLAN VIEW) (PLAN VIEW)

AS.6 OLDCASTLE RESIDENTIAL BUILDING SYSTEM

Equus Design Group ArchitecTs • Planners SUSTAINABLE DESIGN

OLDCASTLE RESIDENTIAL BUILDING SYSTEM

Equus Design Group ArchitecTs • Planners generations to meet their own needs.” without compromising the ability of future development that meets “the needs of the present depleting or damaging them. environments, and using resources without resources without polluting either indoor or outdoor that by conserving energy, water and other design and Development, According to the World Commission on Environment sustainable development with our products. in maximizing opportunities for long-term catchy marketing phrases at Oldcastle. We believe “environmentally friendly” or “green” are not just in the building industry. Labels such as environmental resources is the greatest challenge The responsible management of energy and RESOURCE MANAGEMENT SUSTAINABLE DESIGN is the art of designing buildings that do just sustainable development 1

Sustainable is with budget constraints and customer requirements. in the design of its buildings that are consistent incorporates principles and concepts sustainability planet for total building systems. Oldcastle concrete is the best sustainable material on and for the people who occupy them. Precast Sustainable buildings are good for the environment the following: Sustainable properties of precast concrete include PRECAST CONCRETE SUSTAINABLE PROPERTIES OF concrete building components: in various ways. By using prefabricated precast to reducing initial construction and lifecycle costs factory conditions. Systems building contributes building components, made in quality-controlled integrated assemblage of prefabricated concrete Total Precast Building Systems refers to an TOTAL PRECAST BUILDING SYSTEMS SUSTAINABLE DESIGN & DEVELOPMENT • • • • are beneficial to the planet. The sustainable properties of precast concrete maintenance through the life of building. life cycle and requires less replacement The durability of precast concrete creates a long and energy savings. are greater on-site construction material, labor and faster building closure, the results of which and fast, resulting in reduced construction time Ultimate erection of a systems building is orderly avoided. Job site waste during construction can be Resource Efficient abundant resources: Concrete is made from three of the earth’s most o o o earth limestone, the most abundant mineral on Cement which is predominantly Stone, sand and gravel aggregates Water Highly Durable Recyclable Ecologically Preferable recycled steel, can be recycled again. for its reinforcement, normally obtained from recycled concrete. Furthermore, the steel used Highway Commission encourage the use of Army Corps of Engineers and the Federal sand includes crushed concrete fines. The U.S. concrete, and the definition of manufactured definition of coarse aggregate includes crushed environmental erosion control. The ASTM sidewalks, and bridges, as well for for infrastructure projects such as roads, aggregate in new concrete mixtures particularly Concrete can be crushed and reused as building, the more sustainable benefit it has. the Pantheon, the longer life span of buildings are not expected to last as long 180 a.d., is still in use. While most modern The Pantheon in Rome, a concrete building circa fully hydrate and reach its highest strength. can take years, even decades, for concrete to Concrete actually gets stronger with age. It waste and can be recycled. Furthermore, concrete minimizes construction recreational, commercial or residential uses. restored to nature preserves, parks and other aggregate and limestone quarries can be the fragile ecology that it supports; and limestone is the least disruptive to land and extraction from the earth of aggregate and iron ore mining for steel production, the Compared to logging for wood products and facilities. plants, steel mills, and other manufacturing silica fume, all waste by-products from power components such as fly ash, slag cement, and Furthermore, concrete can also include recycled

SD.1 OLDCASTLE RESIDENTIAL BUILDING SYSTEM

Equus Design Group ArchitecTs • Planners Energy Efficient Excellent Indoor Air Quality achieve beneficial indoor air quality. far the best building material to concrete is by conjunction with these design choices, precast ventilation and air circulation. But, in mechanical systems for appropriate levels of paint; and engineers must carefully design the (VOC) materials such as carpet, partitions and carefully choose low volatile organic compounds reducing indoor air pollutants. Designers must Concrete alone cannot achieve goals of mold spores from the exterior. precast concrete inhibits the penetration of Furthermore, the low permeability rating of requires moist organic nutrients to grow. growth. Concrete is non-organic and mold materials available to inhibit or prevent mold Precast concrete is also one of the best building plague many buildings with “sick syndrome.” of the type off-gassing substances that Precast concrete has extremely low emissions pollutants that lead to “sick building syndrome.” “green” buildings that minimize the type of and occupants are increasingly demanding well-being of the occupants. Building owners The quality of the indoor air is crucial to o o o The thermal mass of concrete saves energy Concrete has low energy requirements for Concrete has low transportation energy air conditioning loads during the day. stored during the night helps to reduce for night heat; similarly, the coolness heat during the day and releases it slowly swings. The mass of the concrete stores in buildings by reducing temperature its production. locally. costs because it is generally produced performance of buildings include the following: technologies. Factors which shape the energy savings in energy efficient building design and Well-informed building owners look for bottom-line ENERGY PERFORMANCE Building Envelope windows, doors, and other closures. outdoor environment including the roof, walls, separates the interior of a building from The building envelope includes everything that o Exterior Walls and an interior wythe of concrete (typically layer of rigid insulation (typically 2” thick), concrete (typically 2”-3” thick), an inner panels, consisting of an exterior wythe Oldcastle’s precast concrete sandwich o o o o o Air Leakage Control Foundations and Basement Slabs Roofs Windows Thin Brick of air and moisture. characteristics for preventing the passage few joints; and concrete has excellent sources of air leakage because there are extremely efficient at reducing potential joints. Precast concrete panels are occurs around windows, doors and building heat and energy loss. Air leakage typically Air leakage is one of the greatest areas slabs is important for energy efficiency. Insulating both foundations and basement energy efficiency. add valuable/useable space while providing and keep buildings cool; and roof gardens White or reflective roofing helps reflect heat heat flow. emissivity (low-e) coatings to suppress gas) between the panes of glass, and low- such as low conductance gas (e.g. argon Energy efficient windows include options construction. air space required in conventional masonry of energy loss such as the weep holes and with embedded brick do not require sources brick projects. Furthermore, precast panels percent of those used in full-bed-depth construction waste are about twenty-five for manufacturing and shipping, projects. The raw clay materials, fuels used an energy efficient solution to all masonry Thin Brick embedded on precast panels is low thermal conductivity (high R-value). and retain heat the insulation provides the thermal mass properties that absorb conservation. The concrete walls include 2”-8” thick), are an ideal product for energy

SD.2 OLDCASTLE RESIDENTIAL BUILDING SYSTEM

Equus Design Group ArchitecTs • Planners Lighting and Daylighting Solar Heat Gain Oldcastle Glass and, to some extent, solar control glass. face can be controlled with shading devices façade receives very little sun and the south on the north and south facades. The afternoon sun and the most amount of glazing glazing in the direction of morning and west orientation will have the least amount of gain. Rectangular buildings placed in an east- contributes heavily to its ability offset solar significantly reduce building energy costs. efficient light fixtures and controls can help to lighting. Effective daylighting and energy significantly reduce the amount of artificial from windows (“daylighting”) can be used to selection and shading devices, natural light Through proper design, including glass “heat island” effect. available from Oldcastle to help reduce the garden waterproofing systems are products colored precast concrete roof pavers, and roof because the surfaces capture solar gain. Light- temperatures are higher than rural areas concern in urban and suburban areas where an effect called “heat islands,” a growing materials such as roofs, paving and walls cause radiation to reduce cooling loads. Dark colored (high-albedo) which helps to reflect solar Precast concrete also is generally a light color design. and contribute to the sustainable aspects of of best glass choices to meet the owner’s needs provide additional information on the variety The can help to control the amount of solar gain. reflectance characteristics of office buildings orientation, shading devices, and light greater the energy consumption. Building of energy. The higher the solar gain, cooling loads, one of the greatest consumers Solar heat gain contributes to the need for high orientation ® , of a building on the site www .oldcastleglass.com , can o o Mechanical and Ventilation Systems Water Efficiency Renewable Energy Systems ventilation systems include: Strategies for energy efficient mechanical and resourceful developments: There are several strategies to create water development. environment and contribute to sustainable energy choices that help to protect the There are an increasing number of renewable include: even cooling, for buildings. Strategies provide heat, light, hot water, electricity, and Solar to provide heating and cooling for buildings. source and sink for a geothermal heat pump temperature of soil or surface water as a heat Geothermal o o o o o o o o o - - - Use of Renewable Energy Systems Digital Climate Controls Waste Heat Recovery Energy Efficient Equipment Ventilation Air Management Recycled Treated Waste Water (Water “Harvesting”) Rain Water Collection & Distribution Water Efficient Landscaping Fixtures Low-Flow and Automatic Shut-Off water and hot heat. collectors to provide energy-efficient hot water or a heat-transfer fluid in Cooling – use of the sun to heat either Solar Hot Water and Space Heating concrete. slowly release the sun’s heat, like building materials that absorb and Daylighting – design features such as Passive Solar Heating, Cooling and and even roof shingles. commercially available as roof panels semiconducting materials, now sunlight into electricity from Photovoltaics - the conversion of – use of the sun’s energy and light to – use of the relatively constant o o electricity for buildings. organic compounds) to produce heat and where it is found primarily in water and abundant element on the earth’s surface, Fuel Cells methane. gaseous fuels such as hydrogen and liquid fuels ethanol, methanol, biodiesel, and to produce a variety of fuels including the wastes, and other waste materials – all used aquatic plants, animal wastes, municipal and residues, wood wastes food and feed crops, agricultural crop wastes dedicated energy crops and trees, agricultural available on a renewable basis, including Biomass – plant derived organic matter – use of hydrogen (the third most

SD.3 OLDCASTLE RESIDENTIAL BUILDING SYSTEM

Equus Design Group ArchitecTs • Planners and prerequisites into five categories: certification. The LEED rating system divides credits can help owners and designers achieve LEED The Oldcastle Precast Residential Building System profits. productivity translating directly into company in LEED certified environments can have increased over the life of building. Furthermore, workers certification can result in energy and cost savings of the green building practices that lead to LEED the most enthusiasm. For example, meeting many benefits that come from certification will generate satisfaction to building owners, tangible economic While civic pride for building “green” can bring some buildings. some are even requiring LEED certification for public are mandating that LEED requirements be met, and government agencies and some states localities being offered for green buildings. Many U.S. are increasing numbers of tax benefits and/or grants LEED certification is typically voluntary, yet there and work. responsible, profitable and healthy places to live promote buildings that are environmentally coalition of building industry leaders working to by the U.S. Green Building Council (USGBC), a (LEED) green building rating system is administered The Leadership in Energy and Environmental Design LEED Certified. certification levels are Platinum, Gold, Silver and the level at which a project can be certified. The The number of points a project earns determines established governmental or trade group standards. Prerequisites and credits are based mostly on Innovation and Design Process Indoor Environmental Quality Energy & Atmosphere Water Efficiency Sustainable Sites ™ ™ ™ ™ ™ CERTIFICATION A listing of some the available resources includes: conservation and high performance building design. designers and owners to learn more about energy There are numerous programs available for RESOURCES LEED credits can be obtained through: Compliance with LEED prerequisites and obtaining many sustainable benefits. determine the potential for maximizing concrete’s the design team for each project in order to LEED certified professionals should be included on .“What is Green Building, and Why Does It 4. .Environmental Council of Concrete 5. 3. .U.S. Green Building Council – 2. Report of the World Commission on 1. o o o o o Matter?” Anne Balough, 2002. Concrete International Martha VanGeem and Medgar L. Marceau, www Organizations - Using Concrete to Maximize LEED 187.htm. www.un.org/documents/ga/res/42/ares42- Nations General Assembly, 1987, Environment and Development to the United (Oldcastle has plants in most U.S. regions) Using regionally produced concrete products is a benefit) building envelope (Concrete’s thermal mass Optimizing energy performance of the reduce stormwater runoff) Use of pervious concrete pavement (to waste) concrete is very efficiently produced with little Construction waste management (precast roads, parking, sidewalks, and fill materials) Recycling concrete (particularly applicable to .concretenetwork.com www .ecco , pp. 69-73, November .org www

.usgbc.org ™ Points , 10. Energy Star - 1 U.S. Environmental Protection Agency – 11. .Sustainable Buildings Industry Council - 9. 13. 12 .U.S. Department of Energy - 8. 6. Achieving Sustainability With Precast . www www www February, 2006. England, D.Sc., A&M Neville Engineering, London Some Aspects of Sustainability 2006. PCI Journal Concrete Paehlke, Natural Resources Canada, 1993. Building Materials Extraction Ecological Carrying Capacity Effects of .epa.go .sbicouncil.org .eere.energy , Martha VanGeem, P.E., LEED A.P., PCI Journal , pp. 42-61, January-February, v/heatisland/about/index.html www .go .energystar v , pp. 72-75, January- , Adam Neville, .go , Dr. Robert v

SD.4 OLDCASTLE RESIDENTIAL BUILDING SYSTEM

Equus Design Group ArchitecTs • Planners CASE STUDIES

OLDCASTLE RESIDENTIAL BUILDING SYSTEM

Equus Design Group ArchitecTs • Planners Melrose II 3 The Juliana Lincoln University Lincoln The Juliana Scranton University 1 4 University of Delaware CASE STUDIES 5 2

CS.0 OLDCASTLE RESIDENTIAL BUILDING SYSTEM

Equus Design Group ArchitecTs • Planners III. II. Hoboken, New Jersey THE JULIANA I. Project Description and courtyard, totaling over 201,000 SF. covered first level parking, bay window projections complex comprised of two four-story buildings with Major Features Project Team 1,624 Precast Pieces Composite Cornice and Trim Formliner Finish (stone) Embedded Brick Finish (9 colors) • • • • • • • • Total Precast Building System: Precaster and Precast Specialty Engineers: Architects: General Contractor: Owner: Special Arch, Pediment, and Curved Panels Elevator and Stair Shaft Walls Stairs and Landings - Interior Exterior Beams and Columns at Parking Level Special Bay Window Floor Projection Slabs Hollow Core Floor and Roof Planks Interior Load Bearing Cross Wall Panels Exterior Load and Non-Load Bearing Panels 408 exterior wall panels 48 landings 48 stairs 244 7- and 8-inch interior wall panels 40 beams 72 columns 696 8-foot wide planks Oldcastle Precast Building Systems Division (local architect-of-record) Bodnar Architects & Assoc. Long Valley, NJ (precast concrete design architects) Equus Design Group, Inc, Belmont, MA Ashley REMI Inc., Hoboken, NJ Kawoz LLC, Hoboken, NJ - - - 128-unit luxury living

CS.A1 OLDCASTLE RESIDENTIAL BUILDING SYSTEM

Equus Design Group ArchitecTs • Planners framed window openings and composite headers over precast ing units, bay projections, thin brick View from street showing stair to liv- the 2nd level Exterior wall panel being erected at buildings enclosed garage in two separate Three levels of living units above one 9 5 1 cornices atop the precast panels Ornamental bracketed composite metal clad bay window window header and cornice, Exterior facade with composite the plant Exterior wall panel being poured in 10 6 2 street 1st level garage entries End view of both buildings at side windows Concrete floor projections at bay precast panels in rhythm with embedded thin brick Metal clad bay window projections 11 7 3 thin brick colors ings showing a variety of different Courtyard view between both build- building stone-like formliner finish at base of Acid etched precast panels with create 2nd level entries Precast panels and stairs used to THE JULIANA 12 8 4 CS.A2 OLDCASTLE RESIDENTIAL BUILDING SYSTEM

Equus Design Group ArchitecTs • Planners counts, and exterior appearance, the structural greatly simplifying system of the project. slight modifications to the unit arrangement and minimal changes to unit layouts, unit Oldcastle was able to implement the total precast Cross Wall Building System with only a brick exterior cavity wall and concrete floor roof plank. The original design of the Juliana project was load bearing metal stud construction with the building. A steel lintel is used between cross walls at the corridor location. Precast floor plank span and bear on the interior precast cross walls and end walls of MODIFIED FLOOR LAYOUT (TYPICAL) ORIGINAL FLOOR LAYOUT (TYPICAL) PRECAST FLOOR LAYOUT (TYPICAL) 3 2 1

CS.A3 OLDCASTLE RESIDENTIAL BUILDING SYSTEM

Equus Design Group ArchitecTs • Planners first level, protected from the weather. sytem for running utilities, there is ample space to provide safe and secure parking on the use of columns and beams to carry the load Cross Walls above, and the Drop-Beam Parking layouts are easily adaptable to the Oldcastle Cross Wall Building System. With the PARTIAL PARKING GARAGE LAYOUT PARTIAL MODIFIED FLOOR LAYOUT 2 1

CS.A4 OLDCASTLE RESIDENTIAL BUILDING SYSTEM

Equus Design Group ArchitecTs • Planners they can be used in place of common building products and still achieve the same design. panels. This example shows the compatibility of precast concrete components and how Oldcastle was able to maintain the original design of facade using precast concrete The modified front elevation designed with precast concrete panels. With minor changes The modified front elevation showing only the exterior concrete panel components. MODIFIED FRONT ELEVATION TO ACCOMODATE PRECAST The original front elevation designed with a brick cavity wall. ORIGINAL FRONT ELEVATION PRECAST FRONT ELEVATION 3 2 1

CS.A5 OLDCASTLE RESIDENTIAL BUILDING SYSTEM

Equus Design Group ArchitecTs • Planners III. II. LINCOLN UNIVERSITY, PENNSYLVANIA LINCOLN UNIVERSITY I. Project Description Major Features Project Team structure was erected during the middle of winter. story 120,000 SF residence hall. The precast • • • • • Total Precast Framing System: Precaster: Architects: General Contractor: Owner: Elevator and Stair Shaft Walls Stairs and Landings Hollow Core Floor and Roof Planks 7-inch Load Bearing Interior Panels Cross Wall System Oldcastle Precast Building Systems Division AP3C Architects, Philadelphia, PA EDIS Company, Wilmington, DE Lincoln University - - - Two phase, four

CS.B1 OLDCASTLE RESIDENTIAL BUILDING SYSTEM

Equus Design Group ArchitecTs • Planners plank Winter erection of precast panels and Setting a precast concrete floor plank cast wall panel Grouting the base of an interior pre- 9 5 1 Exterior brick facade grouted els while floor plank is set and Shoring of interior precast wall pan- Interior precast stairs and landing 10 6 2 Phase 2 panel erection on the left Completed Phase 1 on the right with area Columns and beams at corner study plank along unfinished corridor panels and Interior precast wall LINCOLN UNIVERSITY 11 7 3 Finished exterior building facade ing Stairwell enclosure at end of build- painting to provide a smooth wall ready for Infilling the shoring/bracing anchors 12 8 4 CS.B2 OLDCASTLE RESIDENTIAL BUILDING SYSTEM

Equus Design Group ArchitecTs • Planners TYPICAL UPPER FLOOR LAYOUT

CS.B3 OLDCASTLE RESIDENTIAL BUILDING SYSTEM

Equus Design Group ArchitecTs • Planners PARTIAL UPPER LEVEL FLOOR PLAN PARTIAL STRUCTURAL FLOOR PLAN 2 1

CS.B4 OLDCASTLE RESIDENTIAL BUILDING SYSTEM

Equus Design Group ArchitecTs • Planners ENLARGED TYPICAL SUITE PLAN PARTIAL FLOOR PLAN

CS.B5 OLDCASTLE RESIDENTIAL BUILDING SYSTEM

Equus Design Group ArchitecTs • Planners Bronx, New York MELROSE COMMONS II III. IV. II. I. Project Description ing. townhouse units with courtyard and off-street park- and rental housing comprised of 30 three-story Awards Received Major Features Project Team Over 2,400 concrete pieces Formliner Finish (stone) Embedded Brick Finish • • • • • • • Total Precast Building System: Precaster and Precast Specialty Engineers: Architects: Builder: Developer: • • • • • Cornices Exterior Stairs and Landings Special Three-Sided Stairwell Channels Special Window Head and Sill Projections Hollow Core Floor and Roof Planks Interior Load Bearing Wall Panels Exterior Load and Non-Load Bearing Panels NAHB Energy Value Housing Silver Award database listing BSHF World Habitat Innovative Housing residential award NESEA Northeast Green Building first place HUD Secretary’s Platinum award National Association of Home Builders (NAHB) tions York State to receive Energy Star certifica- First affordable housing development in New Oldcastle Precast Building Systems Division (local architect-of-record) Danois Architects. New York, NY (precast concrete design architects) Equus Design Group, Inc, Belmont, MA Blue Sea Construction LLC, New York, NY MC II LLC, New York, NY - - - - Affordable ownership CS.C1 OLDCASTLE RESIDENTIAL BUILDING SYSTEM

Equus Design Group ArchitecTs • Planners front wall panel Precast cornice, entry channel and being erected Non-load bearing front wall panel Initial pre-construction rendering 9 5 1 header with concrete window jambs Precast concrete projecting window formliner brick veneer, water table and stone Endwall panel with embedded thin veneer compacting concrete over thin brick Pouring concrete panel with self 10 6 2 affordable housing Completed Melrose Commons II position Concrete channel being lifted into shipping to job site Power washing panel prior to MELROSE COMMONS II 11 7 3 Home Builders (NAHB) from the National Association of HUD Secretary’s Platinum Award Precast entry channels and cornices to be shipped job site Exterior wall panel on truck ready 12 8 4 CS.C2 OLDCASTLE RESIDENTIAL BUILDING SYSTEM

Equus Design Group ArchitecTs • Planners BASEMENT 1 ST LEVEL FLOOR PLAN LAYOUTS SITE PLAN 2 ND LEVEL 3 RD LEVEL 3 1 pletes the facade. were used between levels. A decorative precast concrete cornice com- enclosed the front of housing units. Precast stairs and landings load bearing front wall panels and three-sided precast channel pieces tween interior load bearing panels and exterior end unit walls. Non- Melrose Commons II STRUCTURAL PLANK LAYOUT PARTIAL ELEVATION - Floor and roof planks spanned be- 4 2 CS.C3 OLDCASTLE RESIDENTIAL BUILDING SYSTEM

Equus Design Group ArchitecTs • Planners Scranton, Pennsylvania University of Scranton CONDRON HALL III. II. I. Project Description teen weeks. over 108,000 sf of living space, erected in only four- total precast concrete residence hall that contains Major Features Project Team Over 100,000 sf concrete plank Over 500 concrete wall pieces Formliner University Seal and Name Concrete Formliner Finish Embedded Thin Brick Finish • • • • • • Total Precast Building System: Precaster and Precast Specialty Engineers: Architects: Owner: Cornices Interior Stairs and Landings Window Head and Sill Projections Hollow Core Floor and Roof Planks Interior Load Bearing Wall Panels Exterior Load and Non-Load Bearing Panels Oldcastle Precast Building Systems Division (local architect-of-record) Burkavage Design Associates, New York, NY (precast concrete design architects) Equus Design Group, Inc, Belmont, MA University of Scranton - - - Seven-story, 386-bed CS.D1 OLDCASTLE RESIDENTIAL BUILDING SYSTEM

Equus Design Group ArchitecTs • Planners modulating facade projections and recesses of the Precast panels used to create panel prior to pouring of concrete wall Thin brick being layed in formliner name and University seal create embossed precast building Custom formliners were used to 9 5 1 exterior and interior applications Precast concrete walls used for both ity joints used to create visual continu- A combination of mitered and butt colors and coursing patterns Embedded thin brick in different 10 6 2 used to create architectural interest embedded thin brick precast panels A combination of formliner finish and for shipment to job site Exterior wall panel on truck ready areas all clad with precast panels Stairwell, dorm rooms and common 11 7 3 CONDRON HALL way entrance Building as seen from distant high- openings Projected concrete window framed panels made possible with precast spandrel Wide, unobstructed clear spans 12 8 4 CS.D2 OLDCASTLE RESIDENTIAL BUILDING SYSTEM

Equus Design Group ArchitecTs • Planners TYPICAL FLOOR PLAN LAYOUT Condron Hall structure. Precast stairs and landings are used between levels. endwall and stairwell panels are also used to enclose the ends of span between interior and exterior load bearing panels. Load - Using a bearing wall System, floor and roof plank 1 STRUCTURAL LAYOUT 2 CS.D3 OLDCASTLE RESIDENTIAL BUILDING SYSTEM

Equus Design Group ArchitecTs • Planners III. II. NEWARK, DELAWARE University of Delaware I. Project Description 197 two-bedroom units. incorporate 255 one-bedroom apartment units and 1,300 students. The towers have 375,000 SF and story dormitories were designed to accommodate housing built in the United States. The two 17- 1971, is the first total precast high-rise student Major Features Project Team • • • • • • Total Precast Framing System: Architects: General Contractor: Owner: Over 5,000 Precast Concrete Components Fluted Formliner Elevator and Stair Shaft Walls Precast Columns, Beams and Stairs Prestressed Hollow Core Floor and Roof Planks Load Bearing Interior Panels Insulated Load Bearing Exterior Panels Cross Wall System Charles Luckman Associates, New York, NY Inc., Wilmington, DE Joint Venture with Frederic G. Krapf & Sons, Group Ogden Development of Delaware University - - - This project, built in

CS.E1 OLDCASTLE RESIDENTIAL BUILDING SYSTEM

Equus Design Group ArchitecTs • Planners 17-story high-rise dormitory with steel headers for floor plank Wide corridors are made possible A total precast student dormitory 9 5 1 between concrete panels A storefront wall system is installed thermal resistance insulation cores which provide high Exterior wall panels contain foam of one floor per week building The structure was erected at a rate 10 6 2 by smooth spandrels and corners The fluted formliner finish is outlined Combined precast stair and landings floor and roof planks Eight-foot wide hollow core concrete UNIVERSITY OF DELAWARE 11 7 3 the university campus Both high-rise towers as seen from finished with a light sandblast The exterior concrete panels were system Erection of a total precast building 12 8 4 CS.E2 OLDCASTLE RESIDENTIAL BUILDING SYSTEM

Equus Design Group ArchitecTs • Planners TYPICAL TWO BEDROOM APARTMENT PLAN TYPICAL FLOOR PLAN

CS.E3 OLDCASTLE RESIDENTIAL BUILDING SYSTEM

Equus Design Group ArchitecTs • Planners REFERENCES & RESOURCES

OLDCASTLE RESIDENTIAL BUILDING SYSTEM

Equus Design Group ArchitecTs • Planners ƒ ƒ ƒ ƒ ƒ ƒ ƒ Oldcastle Precast Building Systems Division ment and construction. subjects in residential design, planning, develop- cies offer useful information on the wide range of The following associations, organizations and agen- Associations, Organizations, Agencies: www.nahb.org. and building products services, the housing industry, such as mortgage finance associates working in closely related fields within remodelers. The remaining members are 235,000 members are home builders and/or local associations. About one-third of NAHB’s A trade association of more than 800 state and National Association of Home Builders (NAHB) - rental housing. developers and suppliers advocating quality companies consisting of owners, managers, more than 51,000 multifamily housing of 192 state and local affiliates, comprised National Apartment Association www of members drawn from the housing industry, and affordable housing advocacy organization National Housing Conference - A public policy www issues affecting affordable housing, federal agencies on legislative and regulatory housing, and advocate before Congress and professionals working to finance affordable Agencies – A non-profit national association of National Association of Local Housing Finance www apartment advocacy and strategies, industry professional dedicated to multi-family supported association of developers and other National Multi Housing Council – A member products and practices, Department of Energy promoting energy efficient Environmental Protection Agency and the U.S. Energy Star - A joint program of the U.S. www particularly in carbon-fiber reinforced concrete, producers making precast innovations, AltusGroup – A partnership of precast industry ƒ www .nhc.org .nmhc.org .altusprecast.com .nalhfa.org .oldcastlesystems.com . . . www .naahq.org . www .energystar - . A federation .go v . Books, Articles and On-line Resources: ƒ ƒ ƒ ƒ ƒ ƒ ƒ ƒ ƒ ƒ ƒ ƒ ƒ www Industry, RMC Research Foundation, 2006, “LEED Reference Guide,” Ready Mixed Concrete Association ( www.concretethinker.com - a Portland Cement of the Urban Land Institute, MULTIFAMILY TRENDS, a bi-monthly publication Oxford University Press, New York, NY, 1987. Development, “Report on Our Common Future,” World Commission on Environment and January-February, 2006, pp. 42-61. Martha Van Geem, P.E., LEED A.P., PCI Journal, “Achieving Sustainability With Precast Concrete,” 72-75. D.Sc., PCI Journal, January-February, 2006, pp. “Some Aspects of Sustainability,” Adam Neville, www private enterprise and public service, real estate development disciplines, working in members worldwide representing land use and education organization with more than 34,000 Urban Land Institute – A non-profit research and Environmental Design), design through LEED (Leadership in Energy and developers of high-performance green building – a non-profit coalition of trade members and United States Green Building Council (USGBC) Development (HUD), U.S. Department of Housing and Urban www Portland Cement Organization – Precast Concrete Institute – www policy makers in the field of housing, dialogue among educators, researchers and member organization promoting professional Housing Education Research Association – A housing, standards and provide quality affordable stakeholders whose mission is to promulgate multifamily mangers, owners and other industry Association – A member organization of National Affordable Housing Management Canada. representing cement companies in the U.S. and for sustainability design issues. .rmc .housingeducators.org .uli.org .cement.org www -foundation.org . www .nahma.org .cement.org - a trade organization www www . . .hud.go . www www ) web site resource .usgbc.org .uli.org .pci.org v . . . . ƒ ƒ ƒ ƒ ƒ ƒ ƒ ƒ ƒ ƒ ƒ ƒ ƒ RESOURCES REFERENCES & members. and university administrators and faculty www Multi-Family Executive Magazine – D.C., U.S. Green Building Council. Version 2.1 Reference Package, Construction and Major Renovations, LEED-NC U.S. Green Building Council, 2002, Institute. Handbook, Washington, D.C., Urban Land 2000, Multifamily Housing Development Schmitz, Adrienne, and Urban Land Institute, www LEED Green Building Rating System, www Energy Efficient and Renewable Energy Network, www Chronicle of Higher Education, Code Regulations, and Standards, Inc., National Conference of States on Building Codes Federal Regulation 31,676. Guidelines for Building and Facilities,” 1994, “American with Disabilities Act Accessibility McGraw-Hill. Standards for Building Types, De Chiara, and J. Callender, 1990, McGraw-Hill. Residential Development, Time-Saver Standards for Housing and De Chiara, J., J. Panero, and M. Zelnik, eds. 1995, Senior Living, Bradford Perkins, 2004, & Sons, Inc. for College and University Facilities, David Neuman, FAIA, 2003, Sons, Inc. Building Type Basics for Housing Goody, Geoffrey Wooding, Jean Lawrence, 2005, Robert Chandler, John Clancy, David Dixon, Joan .multifamily .usgbc.org/progr .eren.doe.go .chronicle.com John Wiley & Sons, Inc. ex v . www ecutiv , a web-site serving college ams/leed.htm Directory of Building and .ncsbcs.org Building Type Basics for e.com Building Type Basics 2d ed. New York: 3d ed. New York, , John Wiley & Washington, LEED for New . Time-Saver . John Wiley

RR.1 OLDCASTLE RESIDENTIAL BUILDING SYSTEM

Equus Design Group ArchitecTs • Planners S4Equus Design Group, Inc. BS.4 Equus Design Group, Inc. BS.3 Equus Design Group, Inc. BS.2 1. Public Domain - Wikipedia.com BS.1 Oldcastle Precast, Inc. BS.0 Oldcastle Precast, Inc. RP.13 Equus Design Group, Inc. RP.12 Equus Design Group, Inc. RP.11 Oldcastle Precast, Inc. RP.10 Images - Equus Design Group, Inc. RP.9 Images - Equus Design Group, Inc. RP.8 AP3C Architects, Inc. RP.7 Equus Design Group, Inc. RP.6 Equus Design Group, Inc. RP.5 Equus Design Group, Inc. RP.4 Equus Design Group, Inc. RP.3 Equus Design Group, Inc. RP.2 Oldcastle Precast, Inc. RP.1 Equus Design Group, Inc. RP.0 1. Oldcastle Precast, Inc. OP.5 Oldcastle Precast, Inc. OP.4 Oldcastle Precast, Inc. OP.3 1. Thomas H. Kieren OP.2 Oldcastle Precast, Inc. OP.1 Table of Contents – Equus Design Group, Inc. 5. Oldcastle Precast, Inc. 4. Public Domain - Wikipedia.com 3. Equus Design Group, Inc. 2. Jim Harper - Wikipedia.com Photo - Oldcastle Precast, Inc. Photo - Oldcastle Precast, Inc. 2. Equus Design Group, Inc. 3. Oldcastle Precast, Inc. 2. Oldcastle Precast, Inc. S01. Thomas H. Kieren CS.0 Public Domain - Wikipedia.com SD.4 Jon Sullivan - Wikipedia.com SD.3 US Dept. of Agriculture - Wikipedia.com SD.2 SD.1 NASA Equus Design Group, Inc. AS.6 Equus Design Group, Inc. AS.5 Equus Design Group, Inc. AS.4 Equus Design Group, Inc. AS.3 Equus Design Group, Inc. AS.2 Equus Design Group, Inc. AS.1 Oldcastle Precast, Inc. BS.19 Scott System, Inc. BS.18 Equus Design Group, Inc. BS.17 Oldcastle Precast, Inc. BS.16 1-3. Scott System, Inc. BS.15 Fitzgerald Formliner and BS.14 Precast Prestressed Concrete Institute BS.13 Oldcastle Precast, Inc. BS.12 Jeffrey Totaro BS.11 Equus Design Group, Inc. BS.10 Image - Equus Design Group, Inc. BS.9 BS.8 Oldcastle Precast, Inc. Image - Equus Design Group, Inc. BS.7 Images - Equus Design Group, Inc. BS.6 Images - Equus Design Group, Inc. BS.5 5. Oldcastle Precast, Inc. 4. Burkavage Design Associates 3. Oldcastle Precast, Inc. 2. AP3C Architects, Inc. 4. Oldcastle Precast Scott System, Inc. Photo - Oldcastle Precast, Inc. Photo - Oldcastle Precast, Inc. Photos - Oldcastle Precast, Inc. Photo - Oldcastle Precast, Inc. CS.E3 Charles Luckman Associates CS.E2 Oldcastle Precast, Inc. CS.E1 Oldcastle Precast, Inc. CS.D3 1. Burkavage Design Associates CS.D2 Equus Design Group, Inc. CS.D1 Burkavage Design Associates 1. Danois Architects, P.C. CS.C3 1. Danois Architects CS.C2 Oldcastle Precast, Inc. CS.C1 CS.B5 AP3C Architects, Inc. CS.B4 1. AP3C Architects, Inc. AP3C Architects, Inc. CS.B3 1-11. Oldcastle Precast, Inc. CS.B2 AP3C Architects, Inc. CS.B1 1. Bodnar Architect & Associates, Inc. CS.A5 CS.A4 1. Bodnar Architect & Associates, Inc. 1. Bodnar Architect & Associates, Inc. CS.A3 CS.A2 1-3. Equus Design Group, Inc. Thomas H. Kieren CS.A1 stated, unless noted otherwise. Note: All photos and images on page by company CREDITS PHOTO & IMAGE 2. Oldcastle Precast, Inc. 4. Danois Architects, P.C. 3. Danois Architects, P.C. 2. Oldcastle Precast, Inc. 3,4,5,7,9,10,11. Oldcastle Precast, Inc. 2,6,8. Equus Design Group, Inc. 2. Oldcastle Precast, Inc. 12. AP3C Architects, Inc. 3. Equus Design Group, Inc. 2. Equus Design Group, Inc. 2. Oldcastle Precast, Inc. 3. Oldcastle Precast, Inc. 2. Bodnar Architect & Associates, Inc. 4-12. Oldcastle Precast, Inc.

RR.2 OLDCASTLE RESIDENTIAL BUILDING SYSTEM

Equus Design Group ArchitecTs • Planners