Precast Architectural Cladding Panels

carboncastTM

Precast for the 21st Century:lighter, stronger,smarter.

altusgroupTM

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Precast Has Never Looked BetterArchitects have chosen precast concretearchitectural cladding panels for more thanfour decades because they offer exceptionalversatility, speed of enclosure and durability.No other material provides the combinationof colors and textures, fire-resistance, rangeof shapes, acoustical insulation, weather-tightness, long-term durability, low mainte-nance and accelerated construction schedule.However, the weight of the precast concretecomponents can pose challenges for designerswhen developing a building’s steel or concretesuperstructure—especially in recladdingapplications, poor soil or high seismic andwind zones.

Help has arrived. CarbonCast technology canreduce the weight of architectural claddingpanels by up to 66 percent while offeringinsulation values of steady-state R-6 to R-20and improved durability. This is because

CarbonCast panels use non-corrosive, high-strength, resin-bonded carbon fiber reinforcinggrid, C-GRID™, for face reinforcing instead ofsteel. Ultra-strong, 1mm thick C-GRIDrequires less concrete cover than weldedwire, enabling lighter precast sections andeven longer product life, especially in corro-sive environments.

The Biggest Advance in PrecastSince Its InventionCarbonCast Architectural Cladding Panelstake a technology you already know—precast concrete—and improve it by replacingthe steel mesh reinforcing used for shrinkageand temperature-induced crack control witha stronger, non-corrosive, composite materialthat requires less concrete cover andincreases durability.

Lightweight, insulating, back-ribbedCarbonCast Architectural Cladding Panelsemploy a steel-reinforced Vierendeel-liketruss frame attached to a thin, C-GRID-reinforced diaphragm face. Insulating foamforms the ribs and displaces concrete to provide insulation. C-GRID carbon fiber sheartrusses mechanically link the face and trussribs to develop a rigid panel that will with-stand fire, wind and rain.

They also incorporate patented V-Ribsdesigned to create a thermal break with theface of the panel. Solid zones at the panel’sperimeter can be covered at the factory or inthe field with rigid insulation to create a highlyinsulating composite assembly. This designvirtually eliminates the potential for conden-sation and mold in the wall assembly and canincrease net usable or rentable floor area byreducing the width needed for interior studdingand other insulation.

Precast for the 21st Century

CarbonCast technology canreduce the weight of architecturalpanels by up to 66% while offeringinsulation values of steady-stateR-6 to R-20.

CarbonCast Architectural Cladding Panelsspeed installation compared with ordinaryprecast because lightweight CarbonCastpanels can be made larger—requiring fewercrane picks—or can be erected more effi-ciently because more panels can be stagedat one time “under the hook” of the crane,reducing delays caused by jockeying panelsinto position for picking. Depending on design,CarbonCast panels are priced competitivelywith conventional precast or other curtain-wall systems such as brick-veneered masonryor concrete or brick-veneered stud walls.And after factoring in reductions to sub-structure requirements and potential HVACsystem and operating savings, CarbonCastArchitectural Panels can help pay for them-selves—especially in mid- and high-risebuildings.

Carbon Fiber Takes Fighter Jets Beyond Mach 2. Imagine What It Can Do for Your Walls.Super-thin, non-corrosive carbon fiber is thespace-age “enabling technology” that allowsCarbonCast Architectural Cladding Panelsto be lighter, more durable and often lower incost than conventional precast products that

rely on steel mesh face reinforcing. Steelmesh can have problems with corrosion—especially in salt-laden environments—if theconcrete cover is too thin. When steel cor-rodes, it more than doubles in volume andcauses cracking or spalling. It may alsocause unsightly staining when wet.

Exceptionally strong, C-GRID carbon fiberreinforcing grids provide over 6,000 lbs/lf oftensile strength to resist wind loads andother forces acting on architectural claddingpanels. The high strength carbon fibers usedto make C-GRID are over four times strongerthan steel and their close spacing and near-surface placement contribute to superior crackcontrol behavior in concrete structures.

C-GRID’s highly efficient structure, corrosion-resistance and strength allow AltusGroupprecast manufacturers to dramaticallyreduce the amount of concrete cover ineach panel. The result: panels can weigh up to 66 percent less and last even longerthan conventional precast or most othercladding systems.

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O N E A D V A N C E L E A D S T O A N O T H E R

Within the last decade, industrial-grade carbon fiber has been devel-oped for broad use in construction applications. It has many of thesame strength-weight benefits as high-performance carbon fiber, butat a significantly lower cost.

Each carbon fiber “tow” or strand is actually comprised of thousandsof ultra-thin fibers that are bundled together. These tows are assembledperpendicular to each other into a grid using a continuous rotary-formingprocess that also chemically binds them with a heat-cured epoxyresin. The tough epoxy resin and tight orthogonal structure of C-GRIDalso help create a strong mechanical bond with the concrete.

Generally, thinner and more open grid patterns are used near the surface for secondary reinforcing, while thicker and tighter grids areused for more demanding applications such as shear transfer betweenV-Ribs and the face of architectural panels or the wythes ofCarbonCast Insulated Wall Panels.

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Versatility As Infinite As Your ImaginationPrecast concrete gives architects and buildingowners a virtually unlimited array of designand finish options. CarbonCast ArchitecturalCladding Panels are no exception. They pro-vide designers outstanding flexibility interms of:■ Form—Articulations such as reveals, cus-

tom faces, cornices and other shapes. Deepwindow recesses can be included withreduced additional cost.

■ Finish—An almost limitless variety includ-ing colors, applied finishes and veneerssuch as thin brick, tile and stone.

■ Texture—Custom surface texturing canrange from delicate to bold—including polishing, etching and blasting—to yieldthe right unique appearance.

In addition to preventing staining andspalling, C-GRID reinforcement is superior in crack control compared with steel mesh.This unique characteristic is especiallyimportant in architectural panels whereappearance is paramount.

Unlimited Form, Finish, Texture

C O M M E R C I A L / I N S T I T U T I O N A L A P P L I C A T I O N S

Offices

Health Care

Education

Retail

Institutional

Correctional

Cultural

Transportation

Multi-Unit and High-Rise Residential

Mixed Use

From ultra modern tohistorically accurate,

CarbonCast meets yourdesign objectives.

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INDUSTRIAL ANDARCHITECTURAL Appearance RelativeWALL PANELS Uniformity Cost

SHAPES

Perimeter–4 sides ■ $

Perimeter–5 or more sides ■ $$–$$$$

Non-Rectangular ■ $$–$$$

Curved Shapes/Surfaces ■ $$$$$

Punched Shapes (openings) ■ $$

Returns ■ $$$

SIZES

Small Pieces ■ $$$$$

Large Pieces ■ $

Thick Panels (up to 2 hour rated) ■ $

ACCENTS

Plain (no reveals) ■ $

Shallow Reveals (3/4" or less) ■ $ $

Deep Reveals ■ $ $ $

Reliefs (repetitive) ■ $$$

Precast Trims and Projections ■ $$$$$

COLORS

Grey Cement ■ $

White Cement ■ $$

Light Pigments ■ $$

Dark Pigments–high dosage ■ $$$–$$$$

Locally-Sourced Aggregates ■ $

INDUSTRIAL ANDARCHITECTURAL Appearance RelativeWALL PANELS Uniformity Cost

COLORS (continued)

Quartz & Marble Aggregates ■ $$–$$$$

Granite Aggregates (non local) ■ $$–$$$$

Standard Mixes (where available) ■ $

Custom Mixes ■ $–$$

Two Mix Colors per Piece ■ $$$–$$$$

FINISHES

Form Finish ■ $

Paint/Stain/Stucco ■ $$

Light Blast ■ $$$

Medium or Heavy Blast ■ $$

Acid Etched ■ $$

Retarded (exposed aggregate) ■ $$$

Acrylic Brick (where available) ■ $$$–$$$$

Standard High-Repetition Form Liner (ribs, molded brick, stone, etc.) ■ $$$

Custom or Low Repetition Form Liner ■ $$$–$$$$$

Thin Brick or Tile ■ $$$$–$$$$$

Stone Veneer (stone by others) ■ $$$

Honed or Polished (where available) ■ $$$$$

Form-Finished Edges ■ $

Other Edge Finishes ■ $$

S H A P E , S I Z E , A C C E N T A N D F I N I S H O P T I O N S — A P P E A R A N C E A N D C O S T G U I D E

NOTE: Concrete is made from natural materials which vary in the colors they yield over time. Samples will represent a color in the range of colors produced by a mix design. Oldersamples should only be used as a guide for initial color and finish selection. Fresh 12" x 12" samples should always be used to make final color and finish selections. As with naturalstone, mock-ups produced near to the time of actual production should be used to confirm final color and finish selections.

■ Low ■ Medium ■ High

F A C T O R Y A C C E N T S

RevealsPrecast TrimsCornicesBullnosesCustom Ribs and

Other TexturesRadiused Shapes

S U R F A C E S

PrecastBrick Form LinerStone Form LinerMolded ClapboardFactory VeneersTileThin BrickDimensional Stone

F A C T O R Y F I N I S H E S

StainAcid WashLight BlastMedium BlastHeavy BlastExposed AggregateHonedPolished

F I E L D F I N I S H E S & A C C E N T S

Synthetic TrimsClear SealerPaintStain

Less Is More. Way More.With standard precast architectural wall panels,secondary steel reinforcing requires two tothree inches of concrete cover to protect itfrom corrosion, especially in aggressive environments. And overall, traditional precastpanels with reveals are typically six inchesthick and weigh 75 pounds—or more—persquare foot. All that concrete adds weight—and that means added cost.

Non-corrosive C-GRID carbon fiber reinforce-ment eliminates the need for all that extraconcrete. The section properties and reducedweight of CarbonCast wall components—which weigh as little as 27 pounds per square

foot—translate to lower transportation anderection costs, as well as savings on buildingsuperstructure.

Factory Insulation Lowers Weight, Reduces HVAC Demand and Fights MoldTo use less concrete while still providing panelsthat permit deep window recesses, wereplace the displaced concrete with insulatingpolystyrene foam. The added R-value providedby the foam—which can be steady-state R-8or more depending on panel configuration—can improve the thermal efficiency of thestructure, leading to corresponding reductionsin HVAC equipment. Compare that to brick orglass curtainwall assemblies that have no significant or much lower R-values.

The insulating foam provides another impor-tant advantage: it also reduces opportunity formold growth. Compared to uninsulatedcladding, when used with an appropriatevapor retarding gypsum wallboard assembly,the thermally broken, insulated faces ofCarbonCast panels can prevent condensationon the interior side from warm, moisture-laden air. And when the perimeter ribs of aCarbonCast panel are factory- or field-insulatedwith a low permeance rigid foam, the likelihoodof condensation—and mold—in the wall issubstantially reduced.

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Lighter, Stronger, Smarter

Lighter and Better: a Case StudyOn a 34-story building, for example, engineering calculations show that changing to aribbed or rib-backed CarbonCast Architectural Cladding Panel with a 1 3⁄4" concrete facereduced the dead load on each typical exterior column by at least 250,000 pounds, compared with a conventional 6" thick concrete face.

The dramatic weight reduction decreased design loads and gave the design team anoption to reduce the size or number of columns required around the perimeter, resulting in an estimated superstructure cost reduction equal to 25 percent of the architecturalcladding cost.

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Foam Insulation for the Optimum High Performance Insulated Wall System

CarbonCast Insulated Wall Panels can be made with one of three types of rigid foam insulation boards: EPS—Expanded Polystyrene, XPS—Extruded Polystyrene, or ISO—Polyisocyanurate. Each type of foam has unique properties. When used at recommended thicknesses and inconjunction with precast concrete wythes, plastic foams produce assemblies with an M (permeance) of <1.0, qualifying as vapor retarders asdefined by Chapter 2 of the 2003 International Building Code. Designers should select foams for CarbonCast panels based on project-specificrequirements including location, end-use, R-value and budget.

1. R-Value = 1/U = hr x ft2 x °F/Btu; R-Values shown are @ 75°F mean temperature

2. R-value is for unfaced insulation. Faced insulation may deliver higher values.

3. Water vapor permeability, expressed in terms of maximum perms, is forunfaced insulation. Permeability is a property for 1" thick material.Permeance depends on thickness and decreases (improves) as materialthickness increases. Permeability can be improved with the addition offilm facers. Consult manufacturers for specific data and availability.

4. Higher percentages of recycled content are available, but vary by materialand plant location, and may adversely affect other properties such as R-value or compressive strength.

5. These numerical ratings are not intended to reflect hazards presented bythese materials under actual fire conditions.

6. IBC 2003 2603.4 and 2603.5 and IRC R318.2.1 require foam boards to be protected with a 15 minute thermal barrier (e.g., 1/2" gypsum board or anequivalent material, such as 1" of concrete).

7. Water absorbed by unfaced insulation after 24 hours of full immersion in water.

8. EPS and XPS foam boards withstand repeated wetting, are non nutritive,and do not provide a food source for mold growth.

9. Water absorbed by unfaced insulation after 2 hours of full immersion in water.

10. EPS foam boards sourced as PerformGuard™ EPS are specially treated to provide termite resistance in accordance with ICC ES EG 239 (see ICC ES ESR-1006).

PROPERTIES OF FOAM INSULATIONS EPS10 XPS ISO

Typical Density—pcf 1.0, 1.15, 1.35, 1.80 1.30, 1.55, 1.80 2.00

R-Value @ 75°F 1 (ASTM C518) 3.8, 4.0, 4.2 5.0 5.6 2

Water Vapor Permeability/inch 3.5, 3.5, 2.0 1.1 1.0 (ASTM E96) 3

Compressive Strength—psi 13, 15, 25 15, 25, 40 20(ASTM D1621)

Recycled Content 4 ≤15% ≤15% ≤15%

Maximum Service Temperature (°F) 165°F 165°F 250°F

Flamespread (ASTM E84) 5, 6 <75 <75 <75

Smoke Developed (ASTM E84) 5 <450 <450 <450

% Vol. Water Absorption in 24 hours 3%, 3%, 2% .3% NA(ASTM C272) 7, 8

% Vol. Water Absorption in 2 hours NA NA 1.5%(ASTM C209) 9

Cost $–$$ $$$ $$$$

Sources: ASTM C-578 (EPS & XPS) ASTM C1289 (ISO)\ PerformGuard is a registered trademark of AFM R-ControlNA = Not Available

Using less concrete andmore insulating foamreduces energy use andlightens panels.

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CarbonCast technologymay allow you to replace

an existing exteriorenvelope system with a

new high performance one,saving time and expense.

Lightweight and Worry-Free

Architectural Panel Secondary Vertical Rib

Architectural Panel Primary Vertical Rib–A

Architectural Panel Vertical Back Ribs

Architectural Panel Horizontal Back Rib

Architectural Panel Punched Openings

Horizontal Section

Horizontal Section

Elevation

Elevation

Elevation

Eliminate Troubles Before They AriseOther lightweight building envelope alternativescan have problems. Brick wall assemblies areprone to weather delays and susceptible toefflorescence. EIFS has well documented liability issues. GFRC is not widely available and has no insulation value. And hybrid systemsthat have a concrete face supported by a steelstud backing create essentially flat, unarticu-lated panels that severely curtail your designoptions and limit thermal performance.

CarbonCast Architectural Cladding Panelsoffer all the durability, speed and aestheticbenefits of conventional precast concrete,but without all the weight. And without all theworry that accompanies other lightweightsystems.

The Perfect Fit For RecladdingBecause CarbonCast Architectural CladdingPanels can be fabricated as thin as 13⁄4" andas light as 27 pounds per square foot, theyare well suited for recladding applicationswhere thickness, weight and accessibility areissues. In some cases, lightweight CarbonCasttechnology allows you to install a new exteriorenvelope after removing the existing one, savingtime and money in the renovation process.

Keep Unsightly Views Out Of SightCarbonCast Panels can also be an excellentchoice for screen walls around penthouseenclosures, refuse containers and serviceareas. These panels can be as thin as 11⁄4" andcan be finished on both sides where the backof the panel will be exposed to view.

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Architectural Panel Panel-to-Panel Firestop Architectural Panel Rib Firestop Architectural Panel Butt Corner

Vertical Section Vertical Section Horizontal Section

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Improves the Job Site, Not To Mention theRest of the Earth.In addition to their durability and aestheticversatility, CarbonCast Architectural CladdingPanels offer an assortment of environmentalbenefits ranging from erection speed andreduced job site disruption to energy savingsand use of recycled materials.

Score Points With LEEDThe improved insulating properties ofCarbonCast panels lead to more energy-efficient buildings with lower operating costs,making CarbonCast a suitable choice for envi-ronmentally friendly designs. In fact, if pursuingLeadership in Energy and Environmental Design™

(LEED) certification, carbon fiber reinforcedprecast panels can contribute up to 23 Materialsand Resources credits out of the 26 necessaryfor certification.

In addition, C-GRID reinforced precast panelsare more environmentally friendly than otherbuilding enclosure systems because they:■ Use local materials and less concrete■ Make use of some industrial and post-

consumer waste, e.g. primary reinforcing steel, slag, fly ash and rigid foam boards

■ Are lighter, can eliminate other perimetercomponents and reduce structure costs and are more efficient to ship and erect

■ Enhance access around the perimeter of thebuilding and cause less site disruption.

■ Are more thermally efficient—reduced firstcost of HVAC mechanical equipment andlong term energy use

■ Offer integral light colors to reduce ALBEDO,which lowers the “heat island” effect ofbuilding

■ Can be recycled—not a burden on locallandfills

Sustainability and LEED Certification

CarbonCast ArchitecturalCladding Panels lead to more energy-efficientbuildings with loweroperating costs.

Improving the R-Value of awall assembly can help

achieve nearly 40% of thecore credits required forbasic LEED certification.

R E A D Y T O P A S S T H E T O U G H E S T T E S T : Y O U R S

Rigorous laboratory testing has affirmed a number of CarbonCast’s performance characteristics.Below is a sampling of tests that demonstrate the suitability of CarbonCast ArchitecturalCladding Panels for a variety of applications.

C-GRID Material Properties■ Strand Tensile Strength & Cross-Shear Strength■ Behavior Under Sustained Loads & Fatigue Behavior

C-GRID Reinforced Concrete Behavior■ Tension Tests and Pull-out Strength of Shear Grid■ Effect of Temperature on C-GRID used for Shear Transfer■ RILEM Moisture Absorption Test for 1" Concrete Wythes

CarbonCast Architectural Cladding Panel Performance■ Flexural Strength & Uniform Static Load ■ Effects of Thermal Cycling ■ Strand Bond Behavior in Panels Made with Nylon Fiber Reinforced SCC Concrete■ Missile Impact Test■ ASTM E119 Fire Test*

*CarbonCast is safe and fire-ratable when used with gypsum board wall assemblies. Floor-to-floor fire stops can also be cast into panels as required by fire codes.

All the Benefits of PrecastDelivered ready to erect, precast wall panelsavoid the costly scheduling, quality and safetyissues associated with coordinating varioustrades, delays, scaffolding and site congestioncaused by laborers and stored materials andequipment.

For decades, architects and engineers havedepended on the strength, durability anddesign possibilities of precast concrete toachieve:■ Outstanding durability, including fire and

impact resistance

■ Unlimited aesthetic options

■ Excellent design flexibility

■ Peace of mind—quality-oriented, consistentfactory fabrication enables greater qualitycontrol, superior consistency of finish andgreater strength and impermeability

■ Exceptional sound isolating properties

■ Improved resistance to mold compared tomost other systems

■ Fast-track construction—faster to erect,fewer uncontrollable delays, lower costs. (Up to five times faster than field fabrication)

■ Excellent thermal efficiency and weathertightness which can reduce HVAC systemrequirements and energy consumption

■ Low maintenance and life cycle costs

AltusGroup precasters will provide extensivedesign and specification assistance, connec-tion detailing, erection planning, erection andother services to ensure a hassle-free, highquality installation.

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R E P E T I T I O N E F F E C T O N P A N E L S Q U A R E F O O T C O S T

Repetition is a key element in economical precast design and manufacture. You canbenefit from dramatic economies of scale with a “master form” concept that maximizesthe reuse of forms while still allowing for minor variations.

Example panel is 200 square feet and the initial form cost is equal to the production cost of the precast panel.

Use 1 timeUse 10 timesUse 20 times

Use 30 times

Cost of form–per use

PO Box 10097Lancaster, PA 17605

866 GO-ALTUSinfo@altusprecast.comwww.altusprecast.com

altusgroupTM

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AltusGroup Producer Members:Oldcastle Precast, Building Systems DivisionBaltimore, MD; Morrisville, PA; Spokane, WA; South Bethlehem, NYwww.oldcastlesystems.comHigh Concrete GroupTM

Denver, PA ; Lebanon, PA ; Williamsport, PA; Springboro, OH; Paxton, ILwww.highconcrete.comMetromont CorporationAtlanta, GA; Greenville, SC; Charlotte, NC; Nashville,TNwww.metromontusa.comTechFab, LLCAnderson, SCwww.techfabllc.comGate Precast CompanyOxford, NC; Monroeville, AL; Kissimmee, FLJacksonville, FL; Winchester, KY; Nashville, TNwww.gateprecast.comHeldenfels Enterprises, Inc.Corpus Christi, TX; San Marcos, TXwww.heldenfels.comShockey Precast GroupWinchester, VA; Fredericksburg, VAwww.shockeycompanies.comBlakeslee PrestressBranford, CTwww.blakesleeprestress.com

Innovation Partners:A.L. Patterson, Inc.www.alpatterson.comAFM R-Control www.r-control.comDegussa Admixtures, Inc.www.degussa-nafta.comwww.masterbuilders.comEndicott Tile www.endicott.comHigh Concrete Accessories www.producersolutions.comInnovative Brick Systems www.mbrick.comJVI Inc.www.jvi-inc.comLafarge North America, Inc.www.lafargenorthamerica.comMeadow Burkewww.meadowburke.comOwens Corningwww.owenscorning.comSika Corporation (USA)www.sikacorp.comZoltek Corporationwww.zoltek.com

C-GRID is a trademark of TechFab, LLCCarbonCast is a trademark of AltusGroupPhotography of precast concrete construction is for illustrative purposes only.Printed 04-2006

Revolutionary Thinking from the Leading Minds in Precast

AltusGroup, Inc., a company founded by some of the industry’s largest precastersand C-GRID developer TechFab LLC, was incorporated to make CarbonCasttechnology—and future innovations—available throughout North America.

AltusGroup members collectively support more than 25 manufacturing and saleslocations in the United States and over 200 specification-oriented sales, marketingand engineering professionals, and generate more than $1 billion in annual revenue.With pooled research resources, knowledgeable manufacturing engineers and anational network of quality-conscious, PCI-certified plants (www.pci.org), salessupport staff and university collaborators, AltusGroup can help you achieve yourdesign, construction and budget objectives.

Innovative CarbonCast products are available throughout the United States andmany locations in Canada, with an unparalleled network of service and support,offering:■ Extensive testing and the backing of trusted industry leaders■ A central source for complete technical information, including CAD details,

specifications and engineering design standards.■ Local sales and technical representatives to help with design and construction

challenges■ Uniform quality standards and details consistent with the IBC and local codes

Other high performance CarbonCast precast products available from AltusGroup include:■ High Performance Insulated Wall Panels■ Pretopped Double Tees■ Foundation and Wall Panels for Multi-Unit Residential Applications■ Floor and Roof Decks for Multi-Unit Residential Applications

For more information about AltusGroup, CarbonCast precast concrete componentsand the C-GRID technology, call 866-GO-ALTUS or visit www.altusprecast.com.

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