High Performance

Precast Concrete
Envelope Systems
 AIA/CES Quality Statement
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may be addressed at the conclusion of this
presentation.
 NCEES Registered Program
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RCEP.
COURSE DESCRIPTION

• This presentation addresses what high

performance building envelopes are as well as
key elements to their performance. It will discuss
how to use precast concrete wall systems to
meet the latest concrete code requirements such
as continuous insulation and air barriers,
moisture management, thermal mass effect and
effective R values.
• This session will also discuss resilience such as
high winds and earthquakes in order to protect
life and fulfill its intended purpose.
LEARNING OBJECTIVES

• Describe the three basic types of precast

concrete envelope systems
• Describe new envelope code requirements
• Explain thermal mass and how to use it to create
more energy efficient buildings
• Discuss moisture management methodologies
 WHAT IS A HIGH PERFORMANCE
STRUCTURE?
“… integrates and optimizes on a lifecycle basis all major high
performance attributes, including:
• energy and water • sustainability
conservation • functionality
• environment • operational considerations
• safety
• security
• durability
• accessibility
• cost-benefit
• productivity

Energy Independence and Security Act of 2007

401 PL 110-140
HIGH PERFORMANCE PRECAST
Precast concrete is a high performance material
that integrates easily with other systems and
inherently provides the versatility, efficiency,
and resiliency needed to meet the multi-hazard
requirements and long-term demands of high
performance structures.
ATTRIBUTES AND BENEFITS
VERSATILE
Aesthetic Versatility
Virtually any color, form, and texture
Facade integration
Historic compatibility
Structural Versatility
Load-bearing envelopes
Economical sections
Long open spans
Use Versatility
Recyclable
Deconstructive reuse
Adaptive reuse
EFFICIENT RESILIENT
Site Efficiency Structure Durability
Minimal site disturbance Long service life
Negligible waste Barrier wall system
Accelerated construction Functional resilience
Energy and Operational
Multi-Hazard Protection
Efficiency
Scalable performance Storm resistance
Thermally efficient Earthquake resistance
Low life-cycle costs Blast resistance
Risk Reduction Life Safety and Health
Design assist Indoor environmental quality
Reduced detailing and trades Passive fire resistance
Enhanced profitability Meets FEMA 361
TYPES OF HIGH
PERFORMANCE
SYSTEMS
COMMON EXTERIOR WALL SYSTEMS
Precast Concrete
PRECAST CONCRETE WALLS
THREE BASIC TYPES
Sandwich
Solid Wall Panel Thin-shell

• Non-load bearing and load bearing

• Available in essentially any shape and finish
WALL TYPES - SHAPES
Window walls, spandrels, column covers, mullions
WALL TYPES - SOLID
WALL TYPES - SOLID
WALL TYPES – SANDWICH PANELS
WALL TYPES – SANDWICH PANELS
WALL TYPES – THIN SHELL (STUD AND CAVITY)
WALL TYPES – GFRC (Thin Shell)
WALL TYPES – GFRC (Thin Shell)
BARRIER WALL (Face-sealed)
PRECAST
ENVELOPE
ATTRIBUTES
HIGH PERFORMANCE
Efficient
• Use of resources (water, materials, energy)
• Minimal site disturbance
• Accelerated construction
• Reduced construction complexity
• Thermal performance
• Reduced O&M / life cycle costs
• Cost-benefit
HIGH PERFORMANCE
Efficient
• Use of resources (water, materials, energy)
• Minimal site disturbance
• Accelerated construction
• Reduced construction complexity
• Thermal performance
• Reduced O&M / life cycle costs
• Cost-benefit
ENVELOPE PERFORMANCE IS
AFFECTED BY:
• Heat loss/gain for opaque assemblies (i.e.
walls, roofs, etc.)
• Heat loss/gain for fenestration assemblies (i.e.
windows, doors, curtain walls, etc.)
• Amount and quality of fenestration
• Air leakage
• Moisture
ENVELOPE CODES:
• American Society of Heating, Refrigerating and
Air Conditioning Engineers (ASHRAE) 90.1
(2010)
• International Energy Conservation Code
(IECC) (2012)
• U factor or effective R-Value approaches
• Air Barrier
• National Institute of Building Sciences (NIBS)
• International Building Code (IBC) - moisture
DESIGN AND PERFORMANCE

*A*M
• Heat
• Air
• Moisture
HOW WE MANAGE HEAT?
Control heat flow:
• Provide appropriate
insulation (R-value)
• Eliminate thermal
bridging (short circuits)
• Eliminate air and
moisture leaks
• Bonus: Utilize thermal
mass
INSULATION
U-factor is a measure of heat flow – thermal
transmittance through a material. Lower U-factor,
less thermal transmittance.

e.g. double glazing, Low-E, argon

filled, alu. frame with thermal break =
0.36 U -factor (2.8 R-value)

The best insulators have

high R-values, low U factors.
INSULATION
R-Value is a measure of a material’s ability to
resist heat flow. Higher R-value, more resistance
to heat flow, better insulating power.
INSULATION
• Expanded Polystyrene (EPS) –
smalls beads of insulation fused
together
• Extruded Polystyrene (XPS) –
continuous closed-cell structure
• Polyisocyanurate (Polyiso) –
closed-cell
INSULATION
(EPS) (XPS)

R-Value (per in.) 3.9 -4.4 5.0 5.5 – 6.5

INSULATION
ASHRAE 90.1 requires continuous insulation
(ci).
• ci – insulation that is continuous across all
structural members without thermal bridges
other than fasteners and service openings.
Can be located external, internal or integral to
any opaque surface of the envelope.
INSULATION REQUIREMENTS

ASHRAE 90.1- 2010

Mass Wall Steel Frame
Zone Non-Res Res Non-Res Res

5 11.4 ci 13.3 ci 13+7.5 ci 13+7.5 ci

6 13.3 ci 15.2 ci 13+7.5 ci 13+7.5 ci
7 15.2 ci 15.2 ci 13+7.5 ci 13+15.6
ci
8 15.2 ci 25.0 ci 13+7.5 ci 13+18.3
ci
INSULATION – JOINTS, DETAILS
INSULATION – JOINTS, DETAILS
INSULATION – JOINTS, DETAILS
REDUCE THERMAL BRIDGES
ACTUAL THERMAL PERFORMANCE
NOTE: Actual thermal performance will vary
• Hence, an R-19, 2 x 6 stud and cavity wall is not
an R-19 wall. Its closer to an R-9.
R-VALUE CALCULATION
• Steel conducts heat much more efficiently than the
other materials used in a metal stud wall assembly –
thus it has poor thermal resistance properties.
• ASHRAE 90.1 requires a correction in the values of
fiberglass insulation used in steel stud cavity.
 THERMAL MASS
• Absorbs outside and inside heat and slowly releases
• Thermal mass effect delays the onset of peak heating or
cooling loads
• Thermal mass effect may
reduce peak demand/energy
consumption and enable
downsized HVAC systems
• Reduces indoor temperature
fluctuation to improve
occupant comfort
• Thermal mass effect varies by
climate
 THERMAL MASS
• ASHRAE 90.1 Acknowledges the benefit of
thermal mass (Specifies lower min. R-value for
mass walls) Wall type 2007/10
• For example, in a region Mass wall R-11.4ci
like Chicago, the
maximum wall U-factor Steel R-13 +
for mass (concrete) walls Framed R-7.5 ci
is 0.090, and for steel
framed walls the Wood R-13 +
maximum U-factor is Framed R-3.8ci
0.064.
THERMAL PERFORMANCE
Example: 2 ½” ext. concrete, 2” XPS, 7 ½” int. concrete
Note: Edge-to-edge continuous insulation (ci)

Components: R-Value: EXT. AIR FILM

Interior Air Film 0.68 EXT. CONCRETE

STYROFOAM
7 ½” Concrete 0.60
INT. CONCRETE
2” XPS Insulation 10.00 ci INT. AIR
FILM
2 ½” Concrete 0.20
Exterior Air Film 0.17
2 ½” 2” 7 ½”
MATERIAL R-VALUE: 11.65 12”
 OVERALL THERMAL PERFORMANCE
• Thermal Mass improves the overall performance of the envelope

Can help reduce sizing

of HVAC equipment
(tonnage reductions up
to 37%)
Fresno, CA
DESIGN AND PERFORMANCE
H*A*M
• Heat
• Air
• Moisture
MOISTURE MANAGEMENT
Moisture results in mold, damage to interior, etc.
Mold requires a combination of the following conditions:
• Fungal spores settling on the surface
• Oxygen availability
• Optimal temperatures between 40 – 70 °F
• Nutrient available (wood, paper, cellulose based materials)
• Moisture (liquid or relative humidity above 70%)

The first four conditions are met in almost every building.

The key remaining factor is moisture, which may be controlled
by adhering to sound construction practices.
MOISTURE MANAGEMENT
• Moisture directly - prevent leaks – maintain
flashing, joints, roofing, etc.
• Vapor diffusion - the process by which water vapor
migrates through a wall system and it’s
components such as gypsum, concrete, insulation
and paint (molecular level).
• Moisture through exfiltration/infiltration – moisture
in the air that is moved through an envelope
• Manage condensation - Moisture vapor turning to
a liquid on interior surfaces, due to RH and
temperature.
AIR MANAGEMENT
• Exfiltration – outward movement of
air through gaps, cracks, etc. EXTERIOR INTERIOR

• Infiltration – inward movement of air

• Heat and Moisture travel with air

Where do most air leaks occur?

• 5% to 20% of air leakage in
buildings occurs at doors and
windows. EXTERIOR INTERIOR

• 20% to 50% of air leakage occurs

through the walls.
AIR MANAGEMENT
Precast concrete is an air barrier
Average leakage, cfm/ft2 of
Material surface at 0.3 in. H2O
Solid precast concrete wall No measurable leakage
Aluminum foil vapor barrier No measurable leakage
Extruded polystyrene insulation No measurable leakage
Closed cell spray foam insulation 0.0002
½” fibreboard sheathing 0.31
Breather type building membranes 0.0022 – 0.71
Uncoated brick wall 0.31
Uncoated concrete block 0.41
1” expanded polystyrene 0.93
COMBINING FINISHES
DEW POINT
Dew Point Analysis can be used to
determine the potential for condensation
for a given assembly, under a given set
of conditions

Based on:
• The type and position of each
component in the wall assembly.
• The inside temperature and relative
humidity
• The outside temperature and relative
humidity
DEW POINT
Air temperature – size of container
Warm air can contain more water vapor than cold air.

Cold Medium Warm

• Relative humidity (Rh) being how much moisture is
contained in a unit of air compared to how much moisture
could be held by that same unit of air.
• When you change the air temperature, you change the size
of the container
DEW POINT
Same temperature, different RH = diff. dew points

Des Moines Chicago

70 °F 70 °F
30% RH 50% RH

Dewpoint: 37.3°F 50.5°F

DEW POINT
A dew-point calculation chart
% Relative Humidity
## 95 90 85 80 75 70 65 60 55 50 45 40 35 30 25 20 15 10

110 ## ## ## ## ## ## 98 95 93 90 87 84 80 76 72 65 60 51 41
105 ## ## ## 99 97 95 93 91 88 85 83 80 76 72 67 62 55 47 37
100 ## 99 97 95 93 91 89 86 84 81 78 75 71 67 63 58 52 44 32
Temperature °F

95 95 93 92 90 88 86 84 81 79 76 73 70 67 63 59 54 48 40 32
69° Temp
90 90 88 87 85 83 81 79 76 74 71 68 65 62 59 54 49 43 36 32
+ 60% RH
85 85 83 81 80 78 76 74 72 69 67 64 61 58
= 54 50 45 38 32
80 80 78 77 75 73 71 69 67 65 62 59 56 53 50 45 40 35 32
75
55°
75 73 72 70 68 66 64 62 60 58 55 52 49 45 41 36 32
Dew-Point
70 70 68 67 65 63 61 59 57 55 53 50 47 Temp
44 40 36 32
65 65 63 62 60 59 57 55 53 50 48 45 42 40 36 32
60 60 58 57 55 53 52 50 48 45 43 41 38 35 32
55 55 53 52 50 49 47 45 43 40 38 36 33 32
50 50 48 46 45 44 42 40 38 36 34 32
45 45 43 42 40 39 37 35 33 32
40 40 39 37 35 34 32
35 35 34 32
32 32
MOISTURE MANAGEMENT
• With the temperature and
relative humidity, you can
determine the dew point (use
extreme points)
• Analyze heat flow through an
assembly to determine where
condensation will occur: within
the assembly, on the interior of
the assembly, or on the exterior.
• Software programs are aval. to
help
55 degrees
TO CONTROL H*A*M ENVELOPES
SHOULD:
• Use integral, continuous insulation
• Reduce/eliminate thermal bridging
• Utilize thermal mass and account for it in
HVAC design
• Prevent or reduce air infiltration/exfiltration
(air barrier)
• Reduce moisture vapor infiltration (vapor
retarder/barrier)
• Reduce condensation potential by controlling
RH and surface temperatures
PRECAST CONCRETE:
• Can include integral insulation
• Can essentially eliminate
thermal bridging
• Has thermal mass
• Is an air barrier
• Is a vapor retarder at 3 inches
thick

Precast can combine all of these

into one efficient system.
CASE STUDY
CASE STUDY- CATHOLIC UNIVERSITY
CATHOLIC UNIVERSITY - EXTERIOR
WALL SYSTEM
• Precast Concrete SWP with combo thin-brick and
exposed concrete
• 2.5” Ext. conc. – 2” ISO c.i. - 4.5” Int. conc.
• Non-composite design eliminates thermal bowing
• Fiber-composite connectors eliminate thermal bridges
• Wall system has R-value of 14.25
• Integral Insulation with perm rating of 0.03, provides
integral vapor barrier
• There is no cavity for moisture to collect
• Exposed interior concrete maximizes the thermal mass
effect and provides durable finish
• 4 + Hour Fire Endurance Rating
• Sound Transmission Class (STC) Rating of 54
CATHOLIC UNIVERSITY - INTERIOR
WALL SYSTEM
CATHOLIC UNIVERSITY – INTERIOR
WALL SYSTEM

• Dew point
analyses
performed under
extreme summer
and winter
conditions
THERMAL IMAGE – POST OCCUPANCY

• Eastern Exposure; 2.5” Thick Exterior Concrete and Thin-

Brick Veneer Shaded in Blue: 29.9 °F
• Open Windows, Represented in Yellow: 60.6 ° F
DESIGN
PERFORMANCE:
RESILIENT AND
SAFE
HIGH PERFORMANCE
Resilient and Safe
• Durable / long service-life
• Life safety and health
• Indoor environmental quality
• Passive fire resistance
• Effect on the environment
• Functionally resilient:
• Protection from multi-hazards (storms,
earthquakes, blasts, …)
• Able to return to service after an event
IMPACT TESTING
BLAST TESTING
SEISMIC TESTING
SUMMARY
High Performance Structures
• Integrate and optimize ALL relevant attributes
• Focus on long-term performance & reducing
life-cycle costs
• Are built sustainably and also resiliently

High Performance Materials

• Must be versatile, efficient and resilient
• Provide long-term performance
SUMMARY
High Performance Precast Concrete Provides:
• a continuous air barrier, vapor retarder and
insulation efficiently in one system.
• one of the fastest building systems minimizing
negative effects to the site and indoor
environmental quality
• resilient, multi-hazard protection
• the aesthetic versatility to meet challenges and
goals, while reducing detailing and complexity
• for adaptable use and reuse
THANKYOU