PANGASINAN STATE UNIVERSITY

URDANETA CITY CAMPUS, URDANETA CITY, PANGASINAN

COLLEGE OF ENGINEERING AND ARCHITECTURE

ARCHITECTURE DEPARTMENT

RESEARCH WORK NO. RSW – MT – 01

DATE ISSUED: OCTOBER 13, 2022

TITLE: “TYPES OF PRECAST WALL

PANEL SYSTEMS”

COURSE AND TITLE: STUDENT NAME: DATE DUE: FINAL

PP 415 – BUILDING GUMALLAOI, JUDELLE V. OCTOBER 20, RATING:
TECHNOLOGY 5 2022
INSTRUCTOR: COURSE/YEAR/SECTION: DATE
SUBMITTED:
AR. ALVEN T. BACTAD, uap BS-ARCHITECTURE 4-a OCTOBER 14,
FACULTY INSTRUCTOR 2022
 Precast Wall Panel systems

Precast wall panels describe several different types of panel systems:

a. solid concrete panels, 6” or 8” thick

Solid concrete panels are uninsulated self-supporting panels with

only a partition function. They can be used as a facade panel, partition
wall or firewall between two compartments. They are attached to a
specially designed concrete (or steel) structure and come in various
finishes.

B. Insulated concrete panels

also known as composite concrete

panels usually consisting of 2 whythes
of concrete separated by rigid foam
insulation .the inside and outside whythes
usually 3” to 4” thick are connected by
several different proprietary
connector types.

Precast concrete insulated wall

panels offer a quick, environmentally
friendly alternative to building
envelope construction, and with minimal
site disturbance.

Precast wall panel connector types:

1. steel connector
2. fiber composite connector
3. glass fiber polymer connector
4. carbon fiber connectors

These are sometimes called sandwich concrete panels, all these

systems require additional furring on the inside wall for commercial or
residential occupancy. Best use for these types of systems is for industrial
buildings or warehouse walls.

C. Thin Shell Concrete wall panels

Also referred to as composite concrete panels – Metal Stud Crete.

This type of system incorporates a thinner single whythe of concrete
usually 2” thick with light gauge steel framing connected to the concrete .
This cavity back system can be insulated between the framing members, and
the inside wall consisting of steel studs can be enclosed conventionally with
dry wall materials, eliminating the need for additional inside furring. This
type of panel system weighs about 60% less than solid precast wall or
insulated precast walls. This feature reduces the dead load on the
superstructure, and therefore can lower the cost of the structural
materials used in the superstructure for owners.
 Precast concrete wall systems

Precast concrete wall systems can be comprised of a variety

of shapes, and wall types. Typically, precast concrete wall systems
fall into three basic categories: solid, sandwich and thin-shell. These
can be panelised and erected in either a horizontal or vertical
position and used on all types of structures, from residential to
commercial and institutional to industrial. Wall panels can be
designed as non-loadbearing or loadbearing, carrying floor and
roof loads, as well as lateral loads.

Solid Walls

Solid wall panel refers to

walls being made of solid
concrete as opposed to
including integral insulation.
These wall systems require
insulation and an interior
wall/finishing system to
complete the building
enclosures.

Since wall panels are cast

in a flat orientation, the form
side is typically the side that
will be exposed to view in the
final construction. This face
can be made with virtually any
type of finish. The back face is
commonly troweled smooth or
may have a light broom finish.

Typical widths: 1.2m to 4.5m

Typical heights: 3m to 12m
Typical thicknesses: 120mm to 500mm

Finishes: Since wall panels are cast in a

flat orientation, the form side is
typically the side that will be exposed
to view in the final construction
achieving an off-form class 2 finish.
This face can be made with virtually
any type of finish. The back face is
typically troweled smooth or may
have a light broom finish.

Typically, the interior does not

need additional furring and drywall
to create the finished surface.
Sandwich Walls

Insulated sandwich wall

panels can be architectural,
structural, or a combination of
both. The difference between
typical panels and insulated
sandwich wall panels is that the
latter are cast with rigid
insulation "sandwiched" between two
layers, or wythes, of concrete. The
insulation thickness can vary to
create the desired thermal
insulating property ("R" value) for
the wall.

Insulated sandwich wall

panels can be designed to be
loadbearing and support floor
and roof components. They make
an ideal structural element for this purpose, normally by casting a
thicker interior wythe to provide the necessary support. They can
also be non-loadbearing to complete a façade.

As with typical wall panels, the panels are cast in a flat

orientation, so the form side is regularly the side that will be
exposed to view in the final construction. This face can be made with
essentially any type of finish. The back face is generally troweled
smooth or may have a light broom finish.

The structural behavior is either:

Composite in which the wythes are connected using ties through the
insulation that fully transfer loads. The structural performance is
then based on the full thickness of the panel; or

Non-Composite in which the wythes are connected using ties through

the insulation, which limits performance to the individual capacities of
each wythe.

Whether the panel is composite or non-composite depends on

the configuration and material used for the ties. Insulated sandwich
wall panels can be designed to be loadbearing and support floor
and roof components. They make an ideal structural element for
this purpose, typically by casting a thicker interior wythe to
provide the necessary support. They can also be non-loadbearing
to complete a façade.

Finishes: As with typical wall panels, the panels are cast in a flat
orientation, so the form side is typically the side that will be
exposed to view in the final construction. This face can be made with
virtually any type of finish. GFRC panels allow for great aesthetic
details and extensions such as cornices, due to the manufacturing
process. The back face is typically troweled smooth, but is not left
exposed. The back-up systems are often used to attach drywall
and/or other finish materials.

Typical widths: 1.2m to 4.5m

Typical heights: 3m to 12m
Typical thicknesses: 120mm to 500mm

Thin-Shell and GFRC

Thin-shell wall panels consist

of a thin, outer-wythe of concrete,
typically ranging between 1.5 and 3
inches in thickness. This is connected
to a back-up system, usually
constructed of steel framing or
studs, or sometimes concrete. The
back-up system is what connects the
wall panel to the structural system
of the building and often provides
the furring for interior finishes,
such as drywall to be attached.
Many of these systems can also
incorporate a layer of rigid
insulation between the exterior
wythe of concrete and the back-up
system.

Glass Fiber-Reinforced Concrete (GFRC) is a thin-shell system

where the exterior wythe of concrete contains alkali-resistant
glass fibers that is normally sprayed into forms. The fibers
increase tensile, flexural and impact strengths.

Both thin-shell systems reduce the weight of the panels relative

to other precast wall systems. Some can also be designed as
loadbearing.

As with typical wall panels, the panels are cast in a flat

orientation, so the form side is generally the side that will be
exposed to view in the final construction. This face can be made with
virtually any type of finish. GFRC panels allow for great aesthetic
details and extensions, such as cornices.

Lite Walls

Light or "lite" walls are shear walls used in parking structures

cast with an opening in their center to provide visual continuity and
to allow daylight or artificial illumination to penetrate deeper into
an interior. The components provide openness and a feeling of
security. These components should not be confused with "light wells,"
which are internal, open courtyards designed to provide daylight
to the center of parking structures and other buildings.

As with other types of shear walls, lite walls serve as the

lateral force-resisting systems in the structure. They act as
cantilever beams, transferring lateral forces acting parallel to
the face of the wall, from the superstructure to the foundation.

Lite walls are cast horizontally, with three of the four sides
created with a form. These finishes are very smooth and most often
remain "as cast" in the finished construction. The fourth side is
typically troweled to match the other three sides as closely as
possible.
 Types of Connections in Precast Concrete Walls

1. Bolted Connections

The bolted connections are a simplified and fastest method of

erection operation. The final alignment and adjustment can be made
later without tying up crane time. The bolting should be in
accordance with the erection drawings, using material specified by
the designer.

2. Welded Connections

The welded connections are

the most common and typical
connection used in the erection of
precast concrete. These
connections are structurally
efficient and adjust easily to
varying field conditions.

The connections are usually

made by placing a loose plate
between two structural steel
plates that are embedded both in
the cast-in-place or the precast
concrete panel and welded
together.
3. Dowel/Anchor Bolt Connections

In a dowel connection, the strength of dowels in tension or

shear depends on dowel diameter, embedded length, and the bond
developed. The threaded anchor bolts and rebar anchor dowels
that protrude from the foundation are the critical first connection
to precast members.

Structural Design Aspects

The precast walls are designed as blind divider or facade

which does not carry any load. Anyhow, the precast walls must
oppose parallel loads conferred on it due to self-weight, winds, and
quakes.

It is critical to assess the plan, specifying and erection of

precast walls to abstain from forcing undesirable burdens onto
the walls. Loads such as erection, affect, and development related,
and transportation of the precast walls are to be considered in
the design phase.

The joints between the walls must be sufficiently wide to suit

warm extension and differential developments due to season
variations. The divider hole space and go down divider which is
secured with a water-safe film give an optional line of assurance
against water infiltration into the building.

Characteristics of Precast Concrete Walls

1. Thermal Resistance

The precast walls infer their warm execution attributes

basically from the measure of protection set in the depression or
inside the reinforcement divider, which is ordinarily a metal stud
divider.

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.

2. Moisture Protection

The protection for the moisture in the precast walls is of high

importance as the structural members such as columns and beams
are not structurally connected with the precast walls.
 The sealer or the joint seal used in the connections and joints
to prevent the moisture from entering the building. To keep the
uniformity of precast walls and the sealants, pigmented sealants
are used.

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.

3. Fire Safety

The precast walls are manufactured with concrete which has

good fire-resistant material.

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 when a fire occurs that damages the panel
connections and causes a panel to then fall from the building. See
Cast-In-Place Concrete Wall Systems for additional information, as
well as the information included under Resources in this section.

4. Acoustics

A precast wall with a veneer will give comparative execution

with respect to sound transmission from the outside to the inside of
the building.

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.

5. Durability

The durability parameter of the precast walls is the same as

that of concrete. Anyhow, the durability depends on the type of
connections made with the structural member.
 Any irregularities in the member can be rectified by
sandblasting, uncovering total, corrosive washing, hedge pounding,
or different methods.

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.

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.

Most distress and deterioration encountered with precast

concrete wall systems can be attributed to problems during
erection, anchors used to attach panels to the structure, or
corrosion of the embedded reinforcing steel. Panel cracking,
displacements, or other distress conditions can occur at locations
where anchors are inadequately or improperly connected. Poor
construction is often the result of poor quality control and out of
tolerance fabrication or erection of the panels. Also, damage from
handling during construction can result in panel cracking, some of
which may not become evident for several years.

Evaluation of future precast concrete durability is performed

in several ways. Often requirements are specified (air entrainment,
maximum absorption, minimum compressive strength, etc.) to enhance
the durability of the concrete. History of the concrete mix and finish
can also provide useful information. ACI 318 specifies various criteria
for acceptance of a concrete mix. In addition, water-to-cement
ratio, minimum compressive strength, air entrainment range and
other criteria are also listed. If necessary, freeze-thaw testing can
also be conducted in accordance with ASTM C666.

In addition to a precast concrete mix meeting the requirements

and recommendations of ACI 318, evaluation and study of the historic
performance of a particular concrete mix in a similar exterior
environment can also be performed. Petrographic evaluation (ASTM
C856) is also commonly used to evaluate aggregate in an effort to
identify the mineral composition of the concrete and particularly
the aggregate, and based on these observations and past
knowledge of those characteristics, to predict future performance.
Another method of evaluation is to expose samples of the concrete
to an accelerated weathering procedure, and evaluate physical
and mechanical properties for changes.

6. Maintainability

As the walls are manufactured with concrete, which does not

need any maintenance. The connection, sealants, anchorages, and
accessories used in the precast walls need regular maintenance.

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.
 Advantages of Precast Concrete Walls

1. Precast concrete walls act as thermal storage to delay and

reduce peak thermal loads.
2. The precast concrete wall is used as an interior surface which
saves time and money by eliminating the need for separate stud
framing and drywall costs.
3. The precast concrete wall can be used as load-bearing
structures and will save costs by eliminating the need for an
additional structural framing system.
4. Precast concrete walls can be designed to be reused for
future building expansions.
5. Precast concrete’s durability creates a low maintenance
structure, which stands up to harsh climate conditions.
6. Precast concrete colors and finishes can be achieved through
the use of various aggregates, cement, pigments and finishing
techniques.
7. Precast concrete wall panels can utilize a thin brick veneer
that can achieve a traditional appearing facade.
8. Precast concrete walls can be produced with textures
including form liner shapes, artwork, and lettering to provide
distinctive accent treatments.
9. Precast concrete wall panels can have electrical boxes and
conduit cast into the panels, to provide flush electrical
fixtures on walls that are not to be framed out.

Support and Anchorage Systems

The connections for precast concrete panels are an important

component of the envelope system. Precast manufacturers utilize
numerous different types of anchors but they are often
characterized as gravity and lateral types of connections.

The primary purposes of the connection are to transfer load to

the supporting structure and provide stability. The criteria used to
design precast connections including but not limited to:

 Strength
 Ductility
 Volume change accommodations
 Durability
 Fire resistance
 Constructability
 Joints and Joint Treatments

The numerous joints in a precast concrete envelope are an

important aspect of the facade design. The joints between precast
units or between precast and other building components must be
maintained to prevent leakage through the precast wall system.

Joint design should consider the structural, thermal, and all

other factors that affect the performance and movement of a
joint. The joint seal should of course be adequately designed to
withstand the movement of the joint.

Common Backup Wall Elements

In commercial construction, the most common back-up wall

element for architectural precast concrete wall systems is an
insulated, metal stud back-up wall assembly.

Fundamentals

Structural Aspects of Design

Precast concrete wall systems are most often constructed as

a curtain wall or veneer, in which no building loads are transferred
to the concrete panels. Most typically the precast concrete wall
system must resist lateral loads directly imparted on it, such as
from wind and earthquake; as well as vertical loads resulting from
the self-weight of the precast wall system. These loads must be
transmitted through the wall system and secondary structural
elements to the building's structure. Other loads such as erection,
impact, construction related, and transportation must also be
taken into account in the design. It is important to evaluate the
design, detailing and erection of precast panels in order to avoid
imposing unwanted loads onto the panels.

The concrete panels are designed in accordance with PCI

Design Handbook-Precast and Prestressed Concrete (MNL-120),
Design Responsibility for Architectural Precast Concrete Projects
(ACI 533.1R-02), and ACI 318 Structural Concrete Building Code. Steel
elements of a wall system are designed in accordance with AISC
specifications for steel construction. Precast concrete elements
are designed in accordance with ACI and PCI specifications.

Joints between panels must be wide enough to accommodate

thermal expansion and differential movements between panels. Joints
between panels are most commonly sealed with sealant to prevent
water penetration in the wall cavity. The wall cavity space and back
up wall which is usually covered with a water resistant membrane
provide a secondary line of protection against water penetration
into the building.

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.

See the tables for guidance by wall system type for climate-
specific considerations that are imperative to the success of any
enclosure design.
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