8/25/2020

SIMPLIFYING THE BUILDING

ENVELOPE WITH PRECAST
CONCRETE

• Where to find your handouts
• Sign‐in Sheets
• CEU Certificates
• RCEP Account
COURSE • Email: marketing@pci.org
INSTRUCTIONS • Questions for the presenters –
type in the question pane
• How to “raise your hand”

• AIA HSW Credit ( 1.0 LU)

• PDH Credit (1 PDH)

The Precast/Prestressed Concrete Institute (PCI) is a

Registered Provider with AIA/CES. Credit earned on
completion of this program will be reported to CES Records
for AIA members. Certificates of Completion for non-AIA
members are available on request.
ACCREDITATION • This program is registered with the AIA/CES for
continuing professional education.
INFORMATION • As such, it does not include content deemed or
construed to be an approval or endorsement by the AIA
of any material of construction or any method or manner
of handling, using, distributing, or dealing in any
material or product.
• Questions related to specific materials, methods, and
services will be addressed at the conclusion of this
presentation.

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Presenters

Alex Wiltfang Dan Stenzel
Wells Concrete Wells Concrete
Account Manager / Sales Facades Business Development Manager
303.964.7011 507.553.8194
alex.wiltfang@wellsconcrete.com dan.stenzel@wellsconcrete.com

1. Describe different attributes of precast 
concrete envelope systems
2. Explain thermal mass and how to use it to 
create more energy efficient buildings

LEARNING 3. Understand the concept of resiliency and how 
precast/prestressed concrete incorporates it 
to provide multi‐hazard protection

OBJECTIVES
4. Describe aesthetic options for precast 
enclosure systems
5. Strategies to consider for prefabricated 
envelope systems

WHAT IS A
BUILDING
ENVELOPE?
The building envelope is the
physical separation between
the conditioned and
unconditioned environment of
a building including the
resistance to air, water, heat,
light, fire and noise transfer.

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WHAT IS
PRECAST
CONCRETE? Finishing 

Batch Plant Raw Materials
Plant produced, architectural and
structural building components.

Manufactured in quality
controlled, PCI-Certified facilities
where critical variables including
mix design, consolidation,
Wells Concrete, Wells MN
weather conditions, finishes and
tolerances can be closely
monitored and controlled.

WHAT IS Concrete with its primary reinforcement

PRESTRESSED consists of steel strand that is put into

CONCRETE tension, which results in compression of

the concrete.

01. TITLE OF PRESENTATION

PRE- The prestressed component is created by locking

steel strand tight between two fixed abutments.

STRESSING The individual strands are stressed with hydraulic

SET-UP jacks to achieve the design specified tension levels.

01. TITLE OF PRESENTATION

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ADVANTAGES AND BENEFITS OF

PRECAST CONCRETE
• Shortens construction schedule: Generally ½ the schedule of other types of 
construction.
• All weather construction: Bad weather does not affect quality.
• Plant‐controlled conditions: Provides high quality concrete.
• Prestressed concrete: Providing shallow sections, longer spans, and controlled 
cracking.
• Long spans: Up to 110’ roof spans and 60’ high wall panels.
• Durable: Interior of wall panels provide a durable finish suitable for 
a finished surface.
• Fire resistant: Concrete is inherently fire resistant.
• Sound Resistant: Floors STC +50, and IIC +28
• Many finishing and color options: Colored concrete & veneers.

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ADVANTAGES AND BENEFITS OF

PRECAST CONCRETE
• Energy efficient: Concrete stores and releases energy reducing temperature swings.
• Green:
• Precast concrete is 100% recyclable.
• Strand, rebar and plates are produced from 80‐90% recycled material.
• Ingredients are mostly local and readily available.
• The land required to extract aggregates is only a fraction of that required for 
harvesting forest lumber.
• Cement is the only energy intensive ingredient.
• Longer life cycles than other building materials.

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PRECAST CONCRETE

WALL TYPES

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COMMON EXTERIOR
WALL SYSTEMS

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WINDOW WALL, SPANDRELS, COLUMN COVERS

WALL TYPES - SHAPES

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WALL TYPES
Insulated
Solid Thin-shell
Sandwich Panel

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WALL TYPES - SOLID

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WALL TYPES - SOLID

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WALL TYPES – SANDWICH PANELS

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WALL TYPES – SANDWICH PANELS

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WALL TYPES – THIN SHELL (Stud and Cavity)

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ENERGY EFFICIENCY

THERMAL
PERFORMANCE

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EFFICIENT
• Accelerated
construction
• Reduced construction
complexity
• Thermal performance
• Reduced O&M / life
cycle costs
• Cost-benefit

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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

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ENVELOPE
CODES
• ANSI/ASHRAE/IES Standard 90.1‐2016, 
Energy Standard for Buildings except 
Low‐Rise Residential Buildings.
• 2018 International Energy Conservation.
• U factor or effective R‐Value approaches
• Air Barrier
• National Institute of Building Sciences 
(NIBS)
• International Building Code (IBC) ‐
moisture

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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

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INSULATION
• U‐Factor is engineering term which describes 
thermal performance
• U‐Factor represents the transfer of energy 
through conduction
• The lower the U‐Factor, the better the assembly 
performs
• It has typically been applied to building 
components (assemblies), such as windows, 
which are made up of different materials.

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INSULATION
• R‐value represents  • The higher the R‐value, the 
resistance to heat transfer better the insulation
• R‐value tells us how well a  • R‐value only applies to 
construction material  specific materials, not to 
insulates systems

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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.

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INSULATION REQUIREMENTS

IECC MAP ASHRAE MAP

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REDUCE THERMAL BRIDGES

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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.

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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

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THERMAL MASS
Wall type R-Value R-Value
Kansas City Minneapolis
(4A) (6A)
• ASHRAE 90.1 Acknowledges
Mass wall R-9.5 c.i. R-13.3 ci
the benefit of thermal mass
(Specifies lower min. R-value
Wood frame R-13 + R- R-13 +
for mass walls) 3.8 c.i. or
R-7.5 ci or
R-20 R-19 + R-5
c.i.
Steel Frame R-13 + R7.5 R-13 +
c.i. R-12.5 c.i.

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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.

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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.

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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

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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

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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

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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.

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SAFE & RESILIENT

DESIGN
PERFORMANCE

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MULTI-HAZARD RESILIENCY
A precast structure can increase
the safety and security of its
occupants:

• Fire resistant
• Earthquake resistant
• Blast resistant
• Storm / Impact resistant

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FIRE RESISTANCE
Precast concrete is a natural fire
inhibitor
• Non-combustible
• Up to 4-hour fire ratings
• Reduces cost of achieving fire-
ratings
• Structural integrity when exposed to
extreme heat
• Minimizes spread of fire and toxins

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IMPACT RESISTANCE
• Tornados
• Hurricanes
• Man-made blasts

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FINISHES & FEATURES

ARCHITECTURAL
VERSATILITY

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COLOR FACTORS
• Cement - grey, white or combination
• Coarse aggregate - becomes more dominant as surface of concrete is removed
• Fine aggregate – (sand) natural or manufactured
• Pigment – added to matrix
• Coating – applied to surface after manufacturing

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COLOR AND TEXTURE

Light

Medium

Deep

Acid Etch Sand Blast Exposed Aggregate

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FINISHES
• Acid etch
• Sandblast / Abrasive blast
• Water washed
• Formed finish / As-cast
• Polished
• Embedded thin brick, stone,
clay, etc.
• Form liners / Form work
• Graphic Concrete

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Acid Etch / Sandblast

Erik Ramstad Middle School
Fargo, ND

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Acid Etch /Form

Sandblast
Liner

Hyatt Regency Central Station

Bloomington, MN

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Water Wash / Sandblast

ALDI Distribution Center

Faribault, MN

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CAST-IN THIN BRICK

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Cast-In Thin Brick and Polish

Austin Community Center,

Austin, MN

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Cast-In Thin Brick

Augsburg University Center for Science, Business and Religion

Minneapolis, MN

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POLISHING

• Uses a series of
diamond grinding wheels
to polish the concrete
surface, resulting in
exposure of the
aggregates – a similar
appearance to polished
granite.

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St. Cloud Tech High School

St. Cloud, MN

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Form Liner

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Form Liner

One Belleview Station

Denver, CO

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Two form liners

Two concrete mixes

Gabberts / HOM Furniture

Bloomington. MN

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Cornices

Thin Brick

Sandblast

Signage

Sills

Formliner

Jackson Fire Station

Jackson, MN

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SPECIALTY LOGOS AND SIGNS

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GRAPHIC CONCRETE

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GRAPHIC CONCRETE

Dramatic Contrast Slight Contrast

White cement – dark aggregate White cement – white aggregates
Ulappatori Housing - Espoo, Finland Marguerites housing - Paris, France

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• Continuous insulation, air barrier and

vapor retarder in one system.
• Resilient, multi-hazard protection.
• Aesthetic versatility to meet
STRATEGIES TO CONSIDER
challenges and goals, while reducing
FOR
detailing and complexity
PREFABRICATED • One of the fastest building systems
ENVELOPE minimizing negative effects to the site
and indoor environmental quality.
SYSTEMS

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QUESTIONS?
01. TITLE OF PRESENTATION

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THANK YOU
01. TITLE OF PRESENTATION

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