INSULATED PANELS
Report Codifies, Details
Sandwich Wall Panels
Report on the state of the art for precast prestressed sandwich wall panels
consolidates approaches and design examples into one, now-published volume
P
recast prestressed sandwich wall
panels provide a host of
advantages to designers and
contractors, particularly in such
popular construction projects as
industrial buildings, warehouses and
food-processing plants. But their use
varies widely between regions, owing to
different levels of familiarity with the
products and contact with precasters
who create these components. That
knowledge base is about to expand and
the available manufacturing options for
designers to grow with the introduction
this spring of a new report presenting
ASCENT, SPRING 1997
the state of the art for sandwich wall
panels.
Prepared by the Precast/Prestressed
Concrete Institute’s Committee on
Precast Sandwich Wall Panels, the
report presents a detailed examination
28 of the panels, their advantages, and
their design criteria. The report results
from nearly five years of work by the
committee to compile and document
various approaches and techniques used
around the country. “This is the first
time this has ever been done,” explains
consultant Kim Seeber of Gettysburg,
Pa., who chaired the PCI committee.
“Our ultimate goal is to create a
Recommended Practice handbook for
the industry. The first step in that
program is to compile a state-of-the-art
report as to where wall panels are right
now and condense various approaches
into one unified whole.”
Report Now Available
To achieve widespread distribution,
the report was published in the
March/April issue of PCI Journal, with
a number of design examples to follow
in the next issue. The report is a
substantial volume, filling more than
40 pages that discuss the material’s
history, design considerations, thermal
performance, manufacturing processes,
tolerances and repair procedures,
‘This state-of-the-art
presentation will help
eliminate some of the
misunderstandings.’
methods for handling, shipping and
storing, erection techniques, and
inspection needs.
The panels typically consist of two
wythes of precast concrete sandwiched
around a layer of expanded polystyrene
or other insulating material that
measure between two and six inches
thick. The insulation and thermal
breaks provided by the three layers
create high energy efficiencies without
affecting precast construction
techniques. The panels can be load-
bearing or nonload-bearing, and they
offer the advantage of providing an
architectural finish on their exterior
surface, providing both structural
system and an architectural panel in
one piece. Because the panels are
produced in a factory, they offer many
advantages over tilt-up panels produced
on-site, including better quality control
of the finish and installation of the
insulation layers. The ability to
prestress the products also allows the
panels to achieve taller heights than
other types of monolithic panels.
The report’s goal is to take the
various techniques used around the
country to produce and erect these
panels and present them so designers
and contractors are aware of the
possibilities, explains William C.
Richardson Jr., president of Stresscon
Corporation in Colorado Springs,
Colo., and a member of the committee.
“As the popularity of sandwich wall
panels has grown, designers who have
seen the potential for the products have
all devised their own ways of designing
with them,” he says. “This state-of-the-
art report has pulled all of that
information together to create a
consensus for designing with these in
both load- and nonload-bearing
situations.” Adds Seeber, “We tried
very hard to provide recommendations
on how to go about using these panels
without restricting what’s already being
done successfully with them.”
Realizing The Potential
The committee members see the
report as an educational tool as much
for those unfamiliar with the products
as for those actively specifying them,
says John Dobbs, executive vice
president of Hamilton Form Co. Inc.
in Fort Worth, Texas, and current
committee chair. “There are many
architects and engineers who use
precast wall panels almost exclusively
when designing industrial buildings,”
he notes. “But many others don’t
Deublin Company, Waukegan, Ill., J.W. Peters & Sons Inc.
realize the potential that these panels
can offer for providing a load-bearing
member that will support the roof
while supplying an architectural facade
simultaneously. We want to let them
know the full range of what the panels
can do. Educating designers to the
potential is the key, and this report will
achieve that.”
Seeber agrees. “The key problem
arises because the panels are not
completely understood theoretically for
what they can do,” he says. “As a result,
there are differences of opinion about
Top to bottom: Corewall Panel System (wet cast), Spandeck Wall Panel System (wet cast),
Spancrete Wall Panel System (dry cast), Insulated Double Tee Wall Panel System.
how panels work and behave in the
field. This state-of-the-art presentation
will help eliminate some of the mis-
understandings.”
The report doesn’t need to put a
hard sell into its message, he adds. “We
want to stress the intrinsic value of the
panels and the advantages they offer.
The combination of providing a load-
bearing member with a hard,
architectural finish and higher
insulating values is a strong package.”
Here are some of the highlights from
the report:
Chapter One: History. Sandwich
wall panels have been used in the
United States for more than 40 years,
the report notes. Although production
materials have evolved, today’s panels
are manufactured with materials found
in any typical precasting plant. The
panels offer the traditional advantages
as all precast products, including
durability, economy, fire resistance,
large spaces between supports, and use
as shear walls, bearing walls and
retaining walls. They also can be
ASCENT, SPRING 1997
relocated to accommodate building
expansions, and the insulation proper-
ties provide superior energy perfor-
mance. “There is virtually no limit to
the R-Value that can be provided,” it
says.
In general, there are three types of 29
panels:
• Non-composite panels are analyzed,
designed, detailed and manufactured
so the two concrete wythes act
independently. Generally, there is a
structural and a non-structural wythe,
with the structural one being thicker.
• Composite panels feature two panels
that act together to resist applied
loads, allowing the entire panel to
perform as a single unit. This is
accomplished by providing full shear
transfer between the wythes.
• Semi-Composite panels act as a
composite or partial composite panel
during stripping, shipping and
erection, but then perform as non-
composite panels for in-place loads.
(Experience had shown that early
 bond between certain insulation
types and the concrete wythes pro-
vides sufficient shear transfer for
composite action during handling.
Because of thermal forces and move-
ment in the panels, this bond cannot
be depended on permanently.)
Chapter 2: Design Considerations.
The design of sandwich wall panels is
similar to other types of precast
prestressed members once the type of
panel to be designed and manufactured
is selected. The report indicates that the
keys to successful design are twofold: to
ensure that the actual structural behavior
of the panel coincides as nearly as
possible to the predicted behavior and
the original design assumptions; and to
detail the panel and connections to
accommodate anticipated movement.
Wythe thickness typically runs
between two and six inches but can be
made as thick as necessary to achieve Gymnasium & Aquatic Center, Colorado Springs, Colo., Stresscon Corporation.

together and keep the panel intact such aspects as corners, openings and
during handling and service conditions; hanging panels.
shear connectors, which transfer shear Chapter 3: Thermal Performance.
The report points out that concrete
sandwich wall panels provide the best
Wythe thickness structural insulating system available by
typically runs between positioning the most vulnerable portion
of the assembly—the insulation—
two and six inches but between two durable layers of concrete.
“With this insulating technique,” it
can be made as thick as says, “construction time is reduced
ASCENT, SPRING 1997

while the owner receives a durable, low-

30
Thermoform Plastics, White Bear Lake, Minn.,
Fabcon Incorporated.
the imposed loading. Most panels are
made as thin as possible, with the
ultimate thickness usually being
determined by the panel type and final
necessary.
forces between the wythes; and non-
shear connectors, which are tension
elements not capable of transferring
longitudinal shear forces between the
wythes.
Panel widths, thickness, span and
bowing considerations also are spelled
out, as are different elements of flexural
design and levels of prestress required
for each type of panel. In addition, load
bearing design needs for such diverse
maintenance, fire-resistant wall
assembly that delivers the highest R-
Value per unit cost.”
The report stresses that although
there are many insulation types on the
market, insulated concrete sandwich
panels must use a cellular or rigid
SANDWICH
WALL PANEL

;;
EMBEDDED PL
use. For example, the required fire- loads as roof, wind, seismic, soil,

;;
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resistive rating may require a specific temperature and differential shrinkage ANGLE AND
EXP. BOLT INSTALLED
between wythes are delineated. Other
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thickness, while a non-composite panel SHIM
PRIOR TO ERECTION OF PANEL

usually results in a thicker wythe than a sections detail shear wall considerations STACK

composite panel in the same condi-

tions. The use of form liners or reveal
and a host of external connections
among the components, foundation, ;;;;
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;
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strips on the exterior wythe also require roof and floor slabs. BACKER ROD CIP STEM WALL

a thicker panel to satisfy code
requirements.
Other considerations discussed in
detail in this section include wythe
connectors, which tie two wythes
;;;;;
& CAULKING
The final sections in this chapter
look at detailing considerations, and
they outline some of the primary needs
for interaction with other trades, ;;;;;
especially as they relate to finishing Non-shear wall to foundation connections.
insulation because it provides the
material properties most compatible
EXTERIOR FACE COIL ROD OR EXTERIOR FACE

;
;;;; ;
;;;;
with concrete. These properties include REBAR BENT INTO
FINAL POSITION THREADER ROD

moisture absorption, dimensional

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INSULATION CUT BACK INSULATION CUT BACK

stability, coefficient of expansion, and INSERT

SANDWICH
compressive and flexural strengths.
; ;
WALL PANEL
SANDWICH
“The selection of the insulation type to WALL PANEL

enhance energy performance is as

important as the reinforcement needed
; EMBEDDED PL (MAY NEED GUSSET)
;
EMBEDDED PL (MAY NEED GUSSET)

;;;;;;;; ;;;;;;;;
SHIM SHIM EXP. BOLT
to enhance structural performance,” it STACK STACK

says.
The cellular insulation used in
sandwich panels comes in two primary
forms: thermoplastic and ther-
mosetting. Thermoplastic insulations
are better known as molded expanded
polystyrene (beadboard) and extruded
expanded polystyrene (extruded board).
Thermosetting insulations consist of
polyurethane, polyisocyanurate, and
phenolic.
“A concrete sandwich panel is a
unique environment for an insulating
material,” the report points out. During
manufacture of the panel, for instance,
the insulation is exposed to high
temperatures from hydration and
;;;;;;;;
EMBEDDED PL
CIP
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;;;;;;;;
Sample connections for panel bases used for retaining wall
applied heat from accelerated curing.
The insulation being used must exhibit
superior performance capabilities
because of these high temperatures. It
also needs to resist loading from foot
traffic during production, the high
moisture levels from the curing of a
plasticized mix, and the compressive
forces and flexural stresses. Once the
panel is cured and erected, the
insulation also is exposed to continuous
moisture and vapor drive that continue
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CIP
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to affect the insulating material.
In some locations, the report
reminds, freeze-thaw cycles during the
building’s lifetime will produce forces
on the insulation that work to break or
tear apart individual cells. This can be
mitigated by using an alternative
insulation material, such as extruded
polystyrene, which will not be affected
by these environmental changes.
This chapter also outlines pro-
‘Properly constructed
and calculated concrete
sandwich panels can
provide significant
advantages over other
wall systems.’

ASCENT, SPRING 1997

cedures for calculating energy efficiency
in a wall panel, including zonal
methods, isothermal analyses and
thermal-mass requirements. “Properly 31
constructed and calculated concrete
sandwich panels can take full advantage
of energy-efficiency principles and
provide significant advantages over
other wall systems.”
Chapter 4: Manufacture. The
manufacture of sandwich panels
generally follows the same procedures
as other precast prestressed products,
the report explains. These policies are
explained in PCI’s “Manual for Quality
Control for Plants and Production of
Precast and Prestressed Concrete
Products,” Manual MNL-116-85.
There are three standard methods
for casting the panels:
• Wet Cast or normal slump, in which
the panels are made in long-line, steel
Atlanta City Detention Center, Atlanta, Ga., Gate Precast Company. forms with bulkheads separating each
 panel. The bottom wythe strand,
reinforcing steel, and other required
materials are placed, and the first
layer of concrete is placed. Insulation
then is placed with wythe ties that
connect the bottom layer of concrete
and project into the top layer. The
top wythe strand, reinforcing steel,
etc., are placed, and the final layer of
concrete is cast and finished. In some
cases, both the top and bottom
strands are stressed in the initial
production step.
• Dry Cast or zero slump, in which
zero-slump concrete is placed by
machine. This method typically is
used for hollow-core planks and has
been adapted for use with sandwich
wall panels.
• Machine Cast methods developed by
different precasters to produce
various cost efficiencies or benefit
enhancements. Each system uses the
Wet or Dry Cast method as its base
but is produced in a way that the
company has patented for its own
use.
This chapter also explains the
critical need for properly curing the
panels to achieve top quality. Because
of the internal insulation layer, special
ASCENT, SPRING 1997
Harrison County Jail, Ind., Concrete
;
32 Technology Inc.
EMBEDDED PLATE
;
BENT PLATE
EMBEDDED PLATE
LOOSE STRAP PLATE
BAR JOIST
BEAM (BY OTHERS)
SANDWICH
WALL PANEL HOLLOW CORE
SANDWICH
WALL PANEL
FILL ENDS OF CORES
WITH INSULATION
Non load-bearing panels to beam or joist connections.
Henderson County Courthouse, Hendersonville, N.C., Metromont Materials Corporation.
attention has to be given to curing both
top and bottom wythes efficiently to
ensure each receives the proper amount
of heat and cures evenly and
thoroughly. Other key topics addressed
in this section include handling,
potential finishes and detensioning.
Chapter 5: Product Tolerances.
The proper tolerances that can be
achieved in the manufacturing and
erection processes are described in this
Alfa Laval Flow, St. Charles, Mo., Fabcon
Incorporated.
SANDWICH SANDWICH
WALL PANEL WALL PANEL
SLOTTED INSERT
WITH STRAP PLATE SLOTTED INSERT
WITH THREADED ROD
BEAM
BEAM
section, along with the relationships
that exist between different tolerances.
The potential for cracking and how
repairs can be made also are addressed.
In general, sandwich panels may
crack in ways similar to other concrete
wall panels, the report says, and their
occurrence can be predicted and should
be watched for in the erection process.
Repairs can be performed in several
ways, depending on the size of the
crack, but the report points out that the
repairs will not return the cracked panel
to its original uncracked stiffness.
Chapter 6: Handling, Shipping &
Storage. This chapter explains that
panel lengths and widths can vary
widely due to project requirements as
well as to transportation restrictions
and handling-equipment capabilities.
In some areas, for instance, 12-foot-
wide loads can be transported
unescorted while in others the
restriction is for any above 10 feet.
Panels are shipped either on edge or
in a flat position, depending on
equipment being used, finish
requirements, and the flexural design of
the panel. The chapter outlines a
variety of considerations for
determining how the panels will be
shipped and how such factors as job-
site access can impact their delivery.
Chapter 7: Erection. Panel erection,
as with other components, is achieved
by using proper-sized cranes and
rigging, the report details. In most
cases, specific erection diagrams
showing hook-up locations will be
provided by the precaster. Temporary
bracing may be required during the
Lacks Industries, Grand Rapids, Mich.,
Fabcon Incorporated.
Pettit National Ice Center, West Allis, Wis., Spancrete Industries Inc.
Where To Get It
The main body of the PCI’s new
report, “State of the Art of Precast
Prestressed Sandwich Wall Panels,”
was published in the March/April
issue of PCI Journal. Specific design
examples showing the panels in use
were published in the subsequent
issue. To receive copies of those
issues, contact PCI headquarters,
175 W. Jackson Blvd., Suite 1859,
Chicago IL 60604; Ph: 312/786-
0300; Fax: 312/786-0353.
A stand-alone version of the report
will be available shortly as well.
Details on its publication and price
can be obtained from National
Marketing Director Brian Goodmiller
at the same address.
Phillip Morris Plant, Newport News, Va., Tindall Concrete VA Inc.
erection of load-bearing panels, which
most often is achieved with wall braces.
Chapter 8: Inspection. This chapter
reassures the designer that the
inspection of sandwich wall panels
follows normal pre-pour and post-pour
in-plant procedures as outlined in PCI-
Certification standards. (All plants
PCI-Certified to produce sandwich wall
panels must follow specific quality
processes and undergo semi-annual
inspections of their production facilities
to receive certification.) The section
also points out that periodic inspection
of any stored panels awaiting delivery
to a site should be performed to ensure
no problems arise.
The report is seen by committee
members as offering great potential for
expanding the market, both by alerting
designers and engineers to the potential
savings and design enhancements
available and by encouraging more
precasters to produce these com-
ponents. In fact, says Seeber, it has
begun to achieve that result. “I’m
already seeing a better and wider use of
the panel from people who have
reviewed the report prior to its
publication,” he says. “New fabricators
are making the panels available,
creating a higher market penetration,
particularly in the West.”
Hamilton Form’s Dobbs also
anticipates growth, pointing out that
regional distances are not a problem.
“Although most precasters tend to ship
ASCENT, SPRING 1997
within a 200-mile radius of their plant,
some precasters are prepared to ship
virtually anywhere in the country, and
more plants are being set up to produce
these products,” he says. “The market is
growing for them, and the
opportunities are fantastic. No designer 33
should let the thought of lack of
availability deter him from considering
concrete sandwich panels.”
Adds Stresscon’s Richardson, “I
think this report will be a great boon to
engineers and to precasters who aren’t
in this market yet. That in turn will
give designers more options and make
them more aware of the availability and
possibilities. This state-of-the-art
approach has been a long time in
coming.” ■
— Craig A. Shutt