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Overview of Canadian Practices in Architectural Precast Concrete for Building Facades

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Overview of Canadian Practices in Architectural Precast Concrete for Building Facades Special Report Overview of Canadian Practices in Architectural Precast Concrete for Building Facades John R. Fowler, P.Eng. Executive Director Canadian Prestressed Concrete Institute Ottawa, Canada he buildings we construct reflect with the enormous number of finishes T strongly the values, needs and as- and textures which can be produced on pirations of the culture that we live in. the face of architectural precast concrete All our notable new works are built panels, gives a designer tremendous upon a firm base of past experience freedom to select the color, texture and using current science and technology. shape he/she wishes to impart to his/her In the Canadian construction market, building. cladding materials (masonry, glass, High quality precast concrete pro- metal, stone, stucco, tile and precast duced in a plant under controlled con- concrete) compete vigorously for a share ditions is extremely durable and resis- of the $35 billion (Canadian) being tant to weathering and abrasion. The spent annually on building construction. effects of weathering, dirt accumulation Architectural precast concrete en- and air pollution can he minimized by compasses all precast concrete units careful consideration of how rainwater employed as elements of architectural will flow down the face of a building. design. Such units can be structural, The provision of drips, channels and loadbearing by themselves, act as per- scuppers can be used to direct this flow. manent formwork for cast-in-place con- Penetrating sealers are often used to crete or be mainly decorative, repel water from absorbent surfaces, The ability of concrete to flow and as- particularly where soft aggregates and a sume the contours of its mold, combined light colored matrix is used. 24 The adding of large amounts of in- sulation to new buildings following the Synopsis energy crisis in the 1970s can be largely This paper examines trends and ineffective if pressures generated by in Canada for the wind, mechanical systems and stack ef- techniques used manufacture of architectural precast fect cause air to exliltrate and infiltrate concrete spandrel. column cover. the exterior wall. The 1985 National mullion and window panels. The ad- Building Code made air barriers man- vantages and recommended appli- datory on virtually all new buildings. cations of different form materials are Systems assembled at the site are discussed and suggestions are of- often ineffective due to poor workman- fered on how to achieve efficient pro- ship and a lack of coordination among duction of units in a precast factory. the trades. Starting in 1972, the de- The methods of achieving and the end velopment of panelized wall systems in- results of various finishing methods corporating a vented exterior skin of are illustrated. Practical suggestions precast concrete, brick or stone, air gap, for transporting and erecting different insulation and structural precast con- types of panels are given. Many of the crete backing have been successfully concepts are illustrated with examples used in Canada to reduce cladding costs of outstanding products and buildings and build a better wall (Fig. 1). Other where the architects concept was benefits include fast enclosure of a successfully and economically building to shield other trades from bad realized by the use of different archi- weather, reduced construction time and tectural precast concrete panel sys- thinner wall construction to provide tems. more rentable space. The precise sizing of openings and the incorporation of window fastenings and gaskets into architectural precast concrete panels will speed the installa- may completely surround them at the tion of windows and cut glazing costs. ground level. These panels may On some projects the complete frame (c) Window Panels. and window assembly is cast into panels he flat or be heavily sculptured. They may contain a single opening or a series at the factory. of windows. They are either one story in height and made as wide as possible or cast narrower to span vertically for BASIC PANEL TYPES two to four floors. Solid Panels. These panels are While there is a bewildering variety of (d) used to dress tip and enclose any blank architectural precast concrete used wall. Properly designed, these panels everywhere, most building applications can be used to support vertical loads and can be broken down into the following may be used as diaphragms to resist lat- categories: eral forces on a structure. (a) Spandrel and Fascia Panels. These panels are placed to provide horizontal bands around a structure. They may be cast flat, have returns at the top and/or PANEL SIZES bottom and be heavily sculptured. (b) Column Covers and Mullions. Typical panels used for a project These panels are usually narrow and run should he drawn as large as is practica- vertically up a structure. They are often ble. Since many of the manufacturing, used to hide the structural columns and handling and erection costs are inde- PCI JOURNAUJanuary-February 1988 25 pendent of the size of a piece, making both the size and weight of architectural panels larger can substantially reduce precast concrete panels. the cost. To determine the optimum size The size of the cranes in a precast of architectural panels, a close collab- plant and yard is the first constraint. oration between the designers and pre- Making the panel thinner wiII reduce cast supplier is required. The trend over the weight, but care should be taken the past 20 years has been to increase to avoid cracking and warpage during (OiCONVENTIONAL WALL GOOD SYSTEM INTERIOR MEMBRANE DIFFICULT TO MAINTAIN OVER THE ENTIRE WALL SURFACE PRECAST PANEL - DEW POINT FALLS WITHIN STUDS INSULATION THE INSULATION ON THE INTERIOR OF THE BUILDING MEMBRANE -AIR BARRIER DEPENDS ON THE CAULKING GYPSUM BOARD BETWEEN PRECAST PANELS WHICH HAS AN AVERAGE LIFE OF 5 YEARS - WALL MUST 8E MAINTAINED TO BE EFFECTIVE Ib)SANDWICH WALL BETTER SYSTEM EXTERIOR CONCRETE WYTHE - WARM CONCRETE INNER WYTHE EXTRUDED POLYSTYRENE FORMS THE VAPOUR BARRIER INSULATION - INTERIOR AND EXTERIOR STRUCTURAL INTERIOR CAULKED JOINTS ARE SUBJECT CONCRETE WY THE TO PRESSURE DIFFERENCES AND PENETRATION BY WIND DRIVEN METAL FURRING STRIP RAIN IIi. (OPTIONAL) GYPSUM BOARDIOPTIONAL) II- IC }RAIN SCREEN WALL BEST SYSTEM VENTED EXTERIOR FACING (STONE, BRICK, PRECAST) CAVITY IS VENTED TO THE OUTSIDE BY OPENINGS IN THE OUTER 12 MM AIR GAP CAVITY LAYER EXTRUDED POLYSTYRENE. INSULATION EQUALIZED PRESSURE ACROSS THE OUTER LAYER PREVENTS WIND STRUCTURAL INTERIOR DRIVEN RAIN FROM ENTERING CONCRETE WYTHE THE CAVITY METAL FURRING STRIP - ENTIRE WIND LOAD IS TRANSFERRED (OPTIONAL) TO THE INNER WYTHE WHICH IS THE AIR BARRIER GYPSUM BOARD(OPTIONAL) Fig. 1. Typical wall systems incorporating architectural precast concrete wall panels. 26 stripping, stockpiling, yard handling only to resist wind loads. It is being and transportation to the site. Panels are recognized that the rigidity of the panels most vulnerable to cracking at the time together with the interconnection to the of stripping when the concrete strength building frame adds significant stiffness is lowest and the panel is in its weakest to the building structure. Methods of configuration. Stripping panels using analysis to quantify this resistance and multiple pickup points, spreader beams use this benefit in the overall building and rolling blocks will reduce bending design are being developed. and impact forces on thin panels. Some plants cast unbonded post-tensioning tendons into large or irregularly shaped MOLDS panels and stress these tendons prior to removing the panels from the molds. General Most precast plants can handle panels of 15 t (17 tons), with many able to strip Together with the freedom available pieces of40 t (44 tons) or more. through use of architectural precast con- The second constraint is the ability to crete, considerable discipline must be transport the element to the site. All employed by the architect to produce an architectural precast concrete manu- economical design. facturers own or have access to Forms to produce complex architec- specialized hauling equipment which tural shapes are extremely costly to will transport large heavy pieces and make. However, if a large number of conform to highway regulations. To pieces can be produced in each mold, supply large window panels for office then the cost per square metercan be rea- buildings, hill-story 3.2 to 3.7 m (10.5 to sonable and affordable. One way to as- 12.1 ft) high panels must be shipped. sist in this endeavor is to use the master Lengths vary from 9 to 12 m (29.5 to 39.3 mold technique (Fig. 2). Here, all or a ft). In some special cases when ajobsite large number of panels can be produced is near a plant and no overhead obstruc- from a single mold built to accommo- tions are present, enormous pieces can date the largest piece and variously he shipped. subdivided to produce the other sizes The third constraint is the cost and required. Whenever possible, the largest capacity of the cranes at the jobsite. pieces are produced first to avoid cast- Where mobile cranes are used, crane lo- ing on areas worn and damaged through cations, radius and height of lift, and placing and fastening the side form possible obstructions for various sized bulkheads. cranes should be carefully checked. Details of individual panels should Where the contractor's crane is likely to always be left to the precaster. Eleva- be used to erect the architectural panels, tions, wall sections and details of each the capacity of standard and heavy duty different type of wall panel should be tower cranes should be investigated to drawn by the architect. When using determine the economics of building large pieces, if the appearance of larger panels. smaller panels is desired for aesthetic Another advantage of increasing panel reasons, false joints (rustications) can be sizes is structural.
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