Thin Brick Faced Precast

1. ASV Ladysmith, Virginia Thin Brick Faced Precast American Stone Virginia, LLC

2. 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

3. 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

4. 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

5. 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

6. 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.

7. Project Examples • Office and Headquarters facilities for civilian and military users • Administration and warehouse facilities • Parking Structures

8. Fort Lee SCOE office and headquarters building in thin brick with acid washed precast in a spandrel and column design

9. SCOE-1 • APC base panel, TFB columns and spandrels

10. SCOE-2 • APC spandrels in medium acid wash finish

11. SCOE-3 • Interface of APC and TFB panels

12. St Agnes Parking Garage-Baltimore Md • Interesting use of TBP/APC to create the effect of row houses in an urban neighborhood

13. St Agnes Parking Garage • Two brick colorswith acid washed APC

14. Upper Rock Parking Garage • Conventional garage with APC spandrels and TBP stair towers

15. Upper Rock Parking Garage-2 • Projecting APC window surrounds adds depth

16. Ft Lee Central Campus • Office, Administrative and warehouse functions • Masonry and two APC finishes

17. Ft Lee Central Campus • Stacked wall panels with minimal blast loading

18. 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

19. Alignment Issues • Reveal details, brick coursing and panels themselves all need to align within tolerances

20. 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.

21. Basic Structure

22. Three story Building

23. 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)

24. Multi Stories, punched windows

25. Connections for Gravity and Blast • Load bearing haunch connection and blast load tie back in Spandrel and Column format

26. 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

27. Large Panels demand better jobsite access and coordination

28. 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

29. 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)

30. Molds • Casting Area allows custom molds to accommodate any project

31. Brick Formliner • In house production of rubber formliners means control of quality, more customization and less chance of delays

32. Brick Preparation • Brick being coated with bond breaking wax to allow for later washing

33. Mold Construction • Molds constructed on polyester coated wood forms with multiple reveals and blockouts

34. Brick Placement in Molds

35. Pre pour preparation • All mold joint prepped and caulked to prevent leakage from form

36. Quality Control • Panel being Pre pour inspected for conformance to shop drawings

37. Ready for Production • Brick installed, joints caulked, form oiled , sizes checked

38. Concrete Batching • In plant batching with architectural grade equipment

39. Casting • First layer of concrete facing placed and consolidated, reinforcing steel placed and hardware located

40. Embed Placement

41. Finishing • Panels transported to acid washing or sandblasted station

42. Yard Finishing-Patching • Skilled finishers make all the difference in an architectural product

43. Finished Panels in Storage

44. Sandblasted and acid washed panel

45. Special Feature Panels

46. Specialized trailers for transport of large panels

47. Trailers loaded for transport

48. Adequate number of trailers staged for delivery

49. Ready for Installation

50. Erection in Progress