Precast cladding panels

By,
1. Shruti Nargund
2. Spoorti Kamkar
3. Vignesh Malagi
Introduction:
The concept of precast structures also known as prefabricated/ modular structures.
The structural components are standardized and produced in plants in a location away from the building site
Then transported to the site for assembly.
The components are manufactured by industrial methods based on mass production in order to build a large
number of buildings in a short time at low cost
History
Ancient Roman builders invented this technology. In the modern world, precast panelled buildings were pioneered
in Liverpool, England, in 1905. A process was invented by city engineer John Alexander Brodie, whose inventive
genius also had him inventing the football goal net. The tram stables at Walton in Liverpool followed in 1906. The
idea was not taken up extensively in Britain. However, it was adopted all over the world, particularly in Eastern
Europe and Scandinavia.

In the US, precast concrete has evolved as two sub-industries, each represented by a major association. The
Precast Concrete Products industry focuses on utility, underground, and other non prestressed products, and is
represented primarily by the National Precast Concrete Association (NPCA). These focused on precast concrete
elements used in above-ground structures such as buildings, parking structures, and bridges. This industry is
represented primarily by of the Precast/Prestressed Concrete Institute (PCI).

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Precast cladding panels

Precast concrete cladding panels are individual units which are attached to the external frame of a
building to enclose it. They may be load bearing, or they may be just decorative to act as a façade.

The techniques that are used in the manufacture of panels permit a variety of finishes that imitate
virtually any type of architecture at a fraction of the cost.
 Types of precast concrete claddings
Spandrel
A spandrel panel has the same basic
features of a cladding panel, but it also
has a beam incorporated in it. This
allows a greater performance from the
cladding panel than simple building
enclosure.But mainly they are either
storey height spanning from floor to floor,
or spandrel panels forming a sill wall
beneath windows. They are also load
bearing panels.
Load bearing
Load bearing panels are specified
when the engineer decides that their
use will produce the most economic
structural solution. The precast
manufacturer checks the handling
aspects and if necessary will modify
the reinforcement accordingly.Loads
from the floor and/or the structure are
supported by the load bearing cladding.
Non-load bearing
A non-load bearing cladding panel
must be designed, together with its
fittings, to withstand the
appropriate wind forces. Panels
are either be top-hung or
bottom-supported from the building
structure, though both methods
should never be used together on
the same panel.
Features of Precast Cladding Panels

● Cladding panels can incorporate openings, such as windows or doorways, which can be fixed during
manufacture. In this way a finished section of wall is delivered to site, only lacking its internal lining – a
truly fast build method of enclosing a building
● The division and specialization of the human workforce.
● The use of tools, machinery, and other equipment, usually automated, in the production of standard,
interchangeable parts and products.
● Compared to site-cast concrete, precast concrete erection is faster and less affected by adverse
weather conditions
● Plant casting allows increased efficiency, high quality control and greater control on finishes.

Uses

Precast Solid Wall Panels are attractive substitutes for conventional brickwork/block work. They
provide a very high level of finish, eliminating the need of plastering or touch ups. Openings for
doors, windows, ventilators can be easily accommodated during production. These walls can also
be used as compound walls.
Precast Panel Types For Building Envelopes
There are generally four types of precast panels used as part of building envelopes:

1. Cladding or curtain walls

2. Load-bearing wall units
3. Shear walls
4. Formwork for cast-in-place concrete

Precast cladding or curtain walls are the most common use of precast concrete for building envelopes. These
types of precast concrete panels do not transfer vertical loads but simply enclose the space. They are only
designed to resist wind, seismic forces generated by their own weight, and forces required to transfer the weight
of the panel to the support. Common cladding units include wall panels, window wall units, spandrels, mullions,
and column covers. These units can usually be removed individually if necessary.
Load-bearing wall units resist and transfer loads from other elements and cannot be removed without
affecting the strength or stability of the building. Typical load-bearing wall units include solid wall panels, and
window wall and spandrel panels.

Precast concrete shear wall panels are used to provide lateral load resisting system when combined with
diaphragm action of the floor construction. The effectiveness of precast shear walls is largely dependent
upon the panel-to-panel connections.In some cases, precast panels are used as formwork for cast-in-place
concrete. The precast panels act as a form, providing the visible aesthetics of the system, while the
cast-in-place portion provides the structural component of the system.

Insulated or sandwich panels are manufactured in structural and cladding

panels, insulated or sandwich panels are designed to prevent thermal transfer
from the outside of the building to the inside.This is achieved by making a
layered panel with an internal layer of insulating material and specialised
connectors to prevent heat transfer between the external and internal
panels.This system is used in both commercial and residential construction to
achieve high R-values (the measurement of a material’s capacity to resist heat
flow from one side to the other), providing comfortable indoor temperatures
and reducing heating and cooling costs.
BENEFITS:

1. Thermal insulation
All elements of a well-engineered structural precast panel work together to provide a high level of
insulation. Manufacturers often use a combination of concrete and EPS foam that maximizes the foam in
the concrete piece, increasing insulation capabilities. A building constructed of structural precast panels
may reduce energy consumption by as much as 30%.

2. Sustainable materials
Quite simply, a building made with structural precast panels will consume less energy, but an idea that
should be at the heart of any sustainability conversation is product life. The use of concrete dates back to
Roman times and its durability is still on display all across Europe. That raw, ancient building material has
remained virtually unchanged for thousands of years. Many of the materials used in precast concrete are,
as a rule, locally sourced, including the cement, the coarse and fine aggregates, and the steel.

3. Long-term viability and flexibility

Structural precast allows for a very modular building envelope. As business requirements change and
needs evolve, an existing precast building has the flexibility to be expanded and modified. With structural
precast concrete panels, you can add or remove pedestrian doors and dock doors, incorporate daylighting
options, and even remove 75% of a wall. And due to its modular design, total repurposing of a precast
building is entirely possible; churches can become car dealerships, warehouses can become
micro-breweries… the options are only limited by a property owner’s imagination.
4. Quick installation
Speed is a critical hallmark of structural precast construction. “With precast panels, you can establish a
larger completed footprint in a shorter amount of time,” says George Miks, director of engineering.“If you
think of a masonry wall, what they send out to the site are a bunch of blocks that have to be assembled and
constructed out in the field.” When structural precast panels arrive at a job site, the pieces are ready to
install. If things go smoothly out in the field, an experienced crew can install 20 to 30, 12-foot panels in a day.

5. Load-bearing capabilities and wind resistance

Structural precast concrete panels are comprised of high-strength concrete and prestressed steel strand. It’s
relatively routine for precast concrete wall panels have a compressive strength of approximately 7,000 PSI.
You can apply loads in excess of 100,000 pounds to the panels, Miks says. “When you build steel buildings,
for instance, you have to put up perimeter beams and columns and then put steel skin against it. All of that
steel has to support those enclosure panels,” Miks says. “With a structural precast wall system, you don’t
need any of those perimeter beams and columns. You can just tip up the panel and have the roof steel
members themselves attach to the precast. That also means you’ll be spending less on steel.” Precast also
stands up to Mother Nature’s wrath, shrugging off tornadoes, flying projectiles and winds up to 250 miles per
hour.
6. Fire and sound ratings
Concrete is obviously an effective barrier for fire; it simply doesn’t burn well. Precast concrete wall panels
are capable of providing a two- to four-hour fire rating. Precast walls also stay intact even in hot chemical
fires. Warehouses often use precast wall panels as dividers to protect goods on the other side of fire-prone
areas. “The more delay you can create from one side to the other, the better chance of getting people out
safely without incident and also the higher probability of protecting goods and services,” Miks says.

Constructing a commercial structure is a huge undertaking and a significant investment. Whether you’re
charged with the growth of a company, serving your community or building a legacy of your own, precast
construction is a solid, responsible option said Miks.

Advantages:

● Very rapid speed of erection

● Good quality control
● Entire building can be precast-walls, floors,beams,etc.
● Rapid construction on site
● High quality because of the controlled conditions in the factory
● Prestressing is easily done which can reduce the size and number of the structural members.
Advantages that make precast concrete cladding such an appealing option are:

Durability
Assuming the panel design has been carried out with proper thought for rainwater flow over the
surface of the building, it will weather well and not require frequent cleaning.

Economy
Precast cladding offers major cost benefits compared to its natural competitor, curtain walling. Costs
can further be reduced if designers restrict the diversity of the panels, thereby boosting repetition.

Speed
Cladding panel erection can often be completed without the need for external scaffolding. The
process is quick and allows the swift enclosure of the building, a major benefit to all projects.

Quality
Cladding panels are produced under highly controlled factory conditions. The highest grade materials
are used and the concrete mixes are carefully monitored to ensure a quality finish.
Disadvantages:

● Very heavy members

● Camber in beams and slabs
● Very small margin for error
● Connections may be difficult
● Somewhat limited building design flexibility
● Because panel size is limited, precast concrete can not be used for two-way structural
systems.
● Economics of scale demand regularly shaped buildings.
● Need for repetition of forms will affect building design.
● Joints between panels are often expensive and complicated.
● Skilled workmanship is required in the application of the panel on site.
● Cranes are required to lift panels.