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ASV Ladysmith, Virginia. Thin Brick Faced Precast. American Stone Virginia, LLC. What is Thin Brick Faced Architectural Precast.
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ASV Ladysmith, Virginia Thin Brick Faced Precast American Stone Virginia, LLC
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
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
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
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
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.
Project Examples • Office and Headquarters facilities for civilian and military users • Administration and warehouse facilities • Parking Structures
Fort Lee SCOE office and headquarters building in thin brick with acid washed precast in a spandrel and column design
SCOE-1 • APC base panel, TFB columns and spandrels
SCOE-2 • APC spandrels in medium acid wash finish
SCOE-3 • Interface of APC and TFB panels
St Agnes Parking Garage-Baltimore Md • Interesting use of TBP/APC to create the effect of row houses in an urban neighborhood
St Agnes Parking Garage • Two brick colorswith acid washed APC
Upper Rock Parking Garage • Conventional garage with APC spandrels and TBP stair towers
Upper Rock Parking Garage-2 • Projecting APC window surrounds adds depth
Ft Lee Central Campus • Office, Administrative and warehouse functions • Masonry and two APC finishes
Ft Lee Central Campus • Stacked wall panels with minimal blast loading
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
Alignment Issues • Reveal details, brick coursing and panels themselves all need to align within tolerances
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.
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)
Connections for Gravity and Blast • Load bearing haunch connection and blast load tie back in Spandrel and Column format
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
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
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)
Molds • Casting Area allows custom molds to accommodate any project
Brick Formliner • In house production of rubber formliners means control of quality, more customization and less chance of delays
Brick Preparation • Brick being coated with bond breaking wax to allow for later washing
Mold Construction • Molds constructed on polyester coated wood forms with multiple reveals and blockouts
Pre pour preparation • All mold joint prepped and caulked to prevent leakage from form
Quality Control • Panel being Pre pour inspected for conformance to shop drawings
Ready for Production • Brick installed, joints caulked, form oiled , sizes checked
Concrete Batching • In plant batching with architectural grade equipment
Casting • First layer of concrete facing placed and consolidated, reinforcing steel placed and hardware located
Finishing • Panels transported to acid washing or sandblasted station
Yard Finishing-Patching • Skilled finishers make all the difference in an architectural product
