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Lecture 02-Ar Bt 5-Wall Panel System (Precast and Cast-In-place) 1
Lecture 02-Ar Bt 5-Wall Panel System (Precast and Cast-In-place) 1
5:ALTERNATIVE CONSTRUCTION
SYSTEM
LECTURE 02-PRE-CAST AND CAST IN PLACE: WALL PANEL
SYSTEM
MAY 28, 2022
WHAT IS A WALL PANEL SYSTEM?
• MOISTURE PROTECTION
• The most common moisture protection system used with
precast concrete wall systems is a barrier system incorporating
an adequate joint seal. In some cases where additional moisture
protection is needed, the application of a sealer or a concrete
coating is also used. Sealers can be either clear or pigmented if
used as an enhancement of the precast appearance. Film-
forming coatings usually offer a higher level of performance but
will have a significant impact on the appearance of the precast
concrete unit.
• The precast concrete panel should also be designed to provide
the appropriate level of durability for the planned exposure.
Durability can be improved by specifying minimum compressive
strengths, maximum water to cement ratios, and an appropriate
range of entrained air.
• Performance Issues
• THERMAL PERFORMANCE
• Precast wall panels
derive their thermal
performance
characteristics
primarily from the
amount of insulation
placed in the cavity or
within the backup wall,
which is commonly a
metal stud wall in
commercial
construction.
• FIRE SAFETY
• Precast concrete wall systems are not considered to provide any
improvement in fire safety over cast-in-place concrete. In fact, for
high-rise buildings precast concrete panels can pose a serious
safety hazard
• ACOUSTICS
• A precast concrete wall system and cast-in-place facade will
provide similar performance regarding sound transmission from
the exterior to the interior of the building. However, distressed and
open joints between panels can provide a condition in which
sound transmission to the interior may be increased.
• A precast panel with a highly architectural surface
will present challenges in development of a concrete
mix and placement of reinforcing steel. More
complicated profiles in the surface of the panel
usually require more workability in the concrete mix,
better consolidation techniques, and often more
post-production surface repairs.
• Precast panels with differing depths of surface
profiling also require more care in maintaining
sufficient concrete cover over the embedded
reinforcing steel. In summary, the more complicated
the appearance of a precast concrete panel, the
more challenging and important the review and
approval process and quality control program.
• MATERIAL/FINISH DURABILITY
• Precast concrete panels used in wall
systems have many different finishes and
shapes. Often the finish will include the
abrasion or modifying of the surface by
sandblasting, exposing aggregate, acid
washing, bush-hammering, or other
techniques. Each of these finishes presents a
different challenge in producing a durable
precast concrete panel.
• Sandblasting a concrete surface can produce
a surface that is less resistant to moisture
penetration. As a result, a surface treatment,
such as a sealer, should be considered where
this technique is used for finishing.
• MAINTAINABILITY
• When properly constructed precast concrete
panels systems require some maintenance.
The most important maintenance item for
precast panels is the sealant in joints and
protection system, if used. If a sealer or
concrete coating has been used for aesthetics
or to minimize moisture penetration into the
panel, the sealer or coating will require
reapplication. The time frame for the sealant
and surface protection systems varies widely
but usually ranges from every 7 to 20 years
• APPLICATIONS
• Precast concrete wall systems allow a wide
variety of colors, finishes and architectural
shapes. Precast concrete can be used in
environments that allow the use of
conventional cast-in-place concrete.
• In addition, precast concrete may be made in
a controlled environment and erected in an
environment that would not allow site casting
of concrete. The concrete used in precast
panels should be designed to be durable in
the environment in which it will be used.
TYPES OF WALL PANEL SYSTEM
1. FLAT TYPE WALL PANEL SYSTEM
• Wall panel is single piece • Watertight Guarantee
of material,usually flat and • Uniformity of appearance
cut into a rectangular
shape, serves as the visible
• Durability
and exposed covering for a • Ease of replaceability
wall. • Can reduce construction
• ADVANTAGES costs.
• A window wall system spans only a single floor, is supported by the slab
below and above, and is therefore installed within the slab edge.
• A curtain wall is a structurally independent/self-supporting system, typically
spanning multiple stories, and is installed proud of/beyond the slab edge.
WHAT ARE THE SIMILARITIES BETWEEN CURTAIN
WALL AND WINDOW WALL SYSTEMS?
• Cladding – Beyond clear glass, these systems can incorporate panels of metal, stone,
opaque glass, etc.
• Insulation – While they do not have the same insulation value as a solid or framed wall,
these systems do provide some degree of insulation value.
• Structural – While these are not bearing walls (i.e. they do not support the floors above,
and can be removed without any detrimental effect on the overall building structural
system), they transfer their loads to the main building structure, and need to be designed to
resist wind and other lateral loads.
• INSTALLATION AND CONSTRUCTION
• There are two main types of systems: Stick Built and Unitized.
• A Stick-Built system arrives at the site as a kit of parts. The mullions/frames
are assembled on site, and the glass/glazing is installed in place.
• Spacer – The component that separates the glass panes at the edge of
the IGU. It often includes a desiccant material to absorb moisture. Better
spacer materials can improve the overall insulation value of the system.
• Fixed Glazing – As the name implies, these are glass panels that do not
move.
• Anchor – Used with curtain wall systems, the anchor ties the curtain wall to
the slab edges or structural frame. The anchors can be embedded when the
slab is poured or fastened to slab after the slab is in place.
• Fogging of IGUs – This is a result of condensation occurring between the panes of glass, which is caused by a
failure in the seal at the spacer of the IGU. While IGUs have a finite expected useful life, premature fogging may
be an indication of a manufacturing defect or physical damage to the unit.
• Indoor Condensation – This is a result of the surface temperature of the interior frame and/or glass dropping
below the dew point. There may be various possible contributing factors including air leakage; inadequate
specification of the system; excess indoor humidity; or thermal bridging.
https://vertexeng.com/insights/curtain-wall-and-window-wall-
systems/
4. TILT-UP WALL PANEL SYSTEM
• Casting techniques have advanced enough so that it is now possible to cast curved
panels. This requires special formwork to be built on the ground, but following the
first casting, these can be stacked like flat panels if necessary.
• Sustainability and Energy
• Tilt-up panels can be solid concrete, or they may be sandwich-type construction.
Insulation can be incorporated into tilt-up to provide energy efficient construction
with hard exterior wall surfaces. It is common to use extruded polystyrene at 2 to 6
inches thick. Walls can range from R-values of about 2 for uninsulated panels up to
about 32 for walls containing thicker layers of insulation. As building codes require
greater energy efficiency, the thickness of insulation increases. But like all concrete
systems, tilt-up offers high thermal mass, and airtight construction. The panelization
also means fewer joints and reduced air infiltration.
https://gra-gcc.com/blog/precast-vs-tilt-wall-concrete-which-is-
right-for-your-project/