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Thin Brick Faced Precast

ASVLadysmith, Virginia

American Stone Virginia, LLCAmerican Stone Virginia, LLC

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What is Thin Brick Faced Architectural Precast

Thin brick faced precast is conventional Architectural Precast Concrete (APC), section 3450 with portions, or sometimes all, of the exposed to view face covered by a thin section, kiln fired clay masonry unit.

The result is a panel with natural masonry appearance usually accented by areas of smooth or textured architectural precast but with the benefits of APC.

Section 3450 (PCI MNL 117) APC producers are accustomed to the requirements of high end architectural finishes and uniquely qualified to produce this product

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Design Flexibility, Considerations and Benefits

Incorporation of various sections and shapes into design Unlimited color selection and various textures; acid

etched, sandblasted, exposed aggregate Accommodate seismic and blast load design criteria Stacked or gravity loads to structure (Column and

Spandrel) impact on structure and connections Panel size considerations and Limitations Insulated panels possible

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Project and Onsite Considerations

Use of APC shortens the onsite project schedule

Better jobsite efficiency through elimination of conventional masonry scaffolding and a reduction of onsite activity and trades

Less weather sensitive

Get under roof sooner, allowing follow up trades

What is the access for erection equipment and crane reaches

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Green Building Considerations

Use of APC eliminates the jobsite waste generated by conventional masonry

Most APC producers will be located and obtain their raw materials (except the thin brick itself) within 500 miles of the jobsite

Energy cost of manufacturing thin brick is only 18% of the cost of full size brick

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Applications Thin brick/APC can be utilized on any structure where a

masonry appearance is desired.

Panel sizes can be maximized to improve erection efficiency or elements can be reduced in size to accommodate a different architectural appearance.

The use of APC finish as an integral trim feature adds detail and variety with out added cost.

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Project Examples

Office and Headquarters facilities for civilian and military users

Administration and warehouse facilities

Parking Structures

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Fort Lee SCOE office and headquarters building in thin brick with acid washed precast in a spandrel and column design

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SCOE-1 APC base panel, TFB columns and spandrels

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SCOE-2 APC spandrels in medium acid wash finish

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SCOE-3 Interface of APC and TFB panels

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St Agnes Parking Garage-Baltimore Md

Interesting use of TBP/APC to create the effect of row houses in an urban neighborhood

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St Agnes Parking Garage

Two brick colors with acid washed APC

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Upper Rock Parking Garage Conventional garage with APC spandrels and TBP stair towers

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Upper Rock Parking Garage-2 Projecting APC window surrounds adds depth

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Ft Lee Central Campus Office, Administrative and warehouse functions Masonry and two APC finishes

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Ft Lee Central Campus Stacked wall panels with minimal blast loading

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Design Considerations Overall building use and design complexity

Thin brick adds cost compared to a conventionally finished APC panel

Use of thin brick requires careful attention to coursing in detailing, production and erection

On site accommodation (“fudging”) that is available with conventional hand set masonry is not available in APC

Fabrication and erection tolerances must be recognized

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Alignment Issues

Reveal details, brick coursing and panels themselves all need to align within tolerances

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Which basic APC design will be used: Stacked or spandrel-column system

Building Appearance and function Higher end office or more one that is more functional in

nature

Stacked system What is the building story height and blast load requirements Requires lighter structure since no gravity loads Less design flexibility Produces the more typical appearance and shape. (Big

box/warehouse) Generally less expensive to erect and produce since more

repetitive and jobsite erection access is better.

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Basic Structure

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Three story Building

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Spandrel and column design (non –stacked)

More flexible, allows for more shape and complexity

Greater story heights since panels aren't stacking Especially if blast load requirement

Usually includes smaller, lighter panels More panels to erect More panels per trailer= fewer loads and fewer trailers required onsite at a given

time Can use smaller crane (cost partially offsets more panels) Site access requirements usually less demanding than with larger panel stacked

system

Gravity loads transferred to columns or slabs, not to footings Precast connection design more demanding and expensive Better able to accommodate high performance blast (no progressive failure)

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Multi Stories, punched windows

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Connections for Gravity and Blast Load bearing haunch connection and blast load tie back in Spandrel and

Column format

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Panel Sizing

Generally fewer panels= lower cost What is the jobsite access and crane availability Transportation concerns; size weight, costs Plant capacity to produce panel size and weights Typical panels not to exceed 12’ wide and 35’ tall x 8”

thick (42,000#) Wider panels possible but production and shipping costs

increase

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Large Panels demand better jobsite access and coordination

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The Manufacturing Process Color and Finish Selection

Match existing or new sample Color and finish Mock up or sample panel requirement options

Smaller 1’x1’ initial sample Followed by larger sample panel 3’x 3’ to site Onsite mock up with other trades Full size production review onsite or at plant

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Shop Drawings Status of Contract Drawings Plans and Specs Design-Build

APC producer in lead Basic building frame and design from designers Coordination with design team Critical building dimensions must be agreed upon Coordination with other trades critical (structure,

windows)

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Molds Casting Area allows custom molds to accommodate any project

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Brick Formliner In house production of rubber formliners means control of

quality, more customization and less chance of delays

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Brick Preparation Brick being coated with bond breaking wax to allow for later washing

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Mold Construction Molds constructed on polyester coated wood forms with multiple reveals

and blockouts

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Brick Placement in Molds

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Pre pour preparation All mold joint prepped and caulked to prevent leakage from form

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Quality Control Panel being Pre pour inspected for conformance to shop drawings

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Ready for Production Brick installed, joints caulked, form oiled , sizes checked

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Concrete Batching

In plant batching with architectural grade equipment

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Casting First layer of concrete facing placed and consolidated, reinforcing steel placed and

hardware located

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Embed Placement

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Finishing Panels transported to acid washing or sandblasted station

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Yard Finishing-Patching Skilled finishers make all the difference in an architectural product

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Finished Panels in Storage

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Sandblasted and acid washed panel

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Special Feature Panels

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Specialized trailers for transport of large panels

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Trailers loaded for transport

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Adequate number of trailers staged for delivery

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Ready for Installation

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Erection in Progress

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Erected