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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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thin brick faced precast
ASV

Ladysmith, Virginia

Thin Brick Faced Precast

American Stone Virginia, LLC

what is thin brick faced architectural precast
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
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
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
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
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
Project Examples
  • Office and Headquarters facilities for civilian and military users
  • Administration and warehouse facilities
  • Parking Structures
slide8
Fort Lee SCOE office and headquarters building in thin brick with acid washed precast in a spandrel and column design
scoe 1
SCOE-1
  • APC base panel, TFB columns and spandrels
scoe 2
SCOE-2
  • APC spandrels in medium acid wash finish
scoe 3
SCOE-3
  • Interface of APC and TFB panels
st agnes parking garage baltimore md
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
St Agnes Parking Garage
  • Two brick colorswith acid washed APC
upper rock parking garage
Upper Rock Parking Garage
  • Conventional garage with APC spandrels and TBP stair towers
upper rock parking garage 2
Upper Rock Parking Garage-2
  • Projecting APC window surrounds adds depth
ft lee central campus
Ft Lee Central Campus
  • Office, Administrative and warehouse functions
  • Masonry and two APC finishes
ft lee central campus17
Ft Lee Central Campus
  • Stacked wall panels with minimal blast loading
design considerations
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
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
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
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
Connections for Gravity and Blast
  • Load bearing haunch connection and blast load tie back in Spandrel and Column format
panel sizing
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
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
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
Molds
  • Casting Area allows custom molds to accommodate any project
brick formliner
Brick Formliner
  • In house production of rubber formliners means control of quality, more customization and less chance of delays
brick preparation
Brick Preparation
  • Brick being coated with bond breaking wax to allow for later washing
mold construction
Mold Construction
  • Molds constructed on polyester coated wood forms with multiple reveals and blockouts
pre pour preparation
Pre pour preparation
  • All mold joint prepped and caulked to prevent leakage from form
quality control
Quality Control
  • Panel being Pre pour inspected for conformance to shop drawings
ready for production
Ready for Production
  • Brick installed, joints caulked, form oiled , sizes checked
concrete batching
Concrete Batching
  • In plant batching with architectural grade equipment
casting
Casting
  • First layer of concrete facing placed and consolidated, reinforcing steel placed and hardware located
finishing
Finishing
  • Panels transported to acid washing or sandblasted station
yard finishing patching
Yard Finishing-Patching
  • Skilled finishers make all the difference in an architectural product
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