Precast Housing Structures

1. Precast Housing Structures

2. This program is registered with the AIA/CES for continuing professional education. As such, it does not include content that may be deemed or construed to be an approval or endorsement by the AIA of any material of construction or any method or manner of handling, using, distributing, or dealing in any material or product. Questions related to specific materials, methods, and services will be addressed at the conclusion of this presentation. • “Precast/Prestressed Concrete Institute” (PCI) is a Registered Provider with The American Institute of Architects Continuing Education Systems. Credit earned on completion of this program will be reported to CES Records for AIA members. Certificates of Completion for non-AIA members are available on request.

3. Learning Objectives After viewing this program, you will be able to: • Identify the different precast/prestressed concrete systems used in housing • Explain the benefits of using precast/prestressed concrete in housing structures • Discuss the design considerations for precast/prestressed concrete housing structures

4. Agenda • Housing Design Challenges • Benefits of Precast/Prestressed Concrete • Precast Housing Applications • Early Precaster Involvement • Precast Housing Design Considerations • Precast Housing “Design Project” • PCI Resources • Questions/Discussion

5. Housing Design Challenges • General challenges for all housing? • Specific challenges? • Single-Family • Multi-Family • Student Housing • Condominiums • Hotels/Motels • Retirement Housing • Assisted Living

6. Housing Design Challenges • Fit in with campus architectural style (student dorms) • Create open spaces on lower floors for gathering areas, dining room, etc. • Create secure balconies • Construct the building quickly to speed occupancy or shorten loan periods • Provide high quality, low-maintenance facade • Create attractive appearance for both tenants and neighborhood • Eliminate noise or vibration between floors or rooms • Minimize floor-to-floor heights to meet zoning codes and maximize the number of levels • Withstand damage from fire, users, moisture, severe weather, vermin, earthquakes • Minimize energy use

7. Benefits of Precast • Low Maintenance • Acoustical Control • Mold Resistance • Controlled Environments • Expansion Capabilities • Economy • Design Flexibility • Controlled Production • PCI-Certified Quality • Safety & Security • Sustainability • Layout Flexibility

8. Design Flexibility • Your choice of color • Simulated textures • MNL-116 tolerances

9. Design Flexibility Exterior finish materials • Stucco • Paint • Ceramic tiles • Brick veneer • Stone veneer • Terra cotta

10. Controlled Production Casting components under factory-controlled conditions benefits a project in many ways: • More control over final appearance • Tighter tolerances • Precaster as team member • Elimination of several trades and materials • Production regardless of weather conditions

11. PCI-Certified Quality Independent auditors… • test raw materials • inspect finished products • inspect internal QA/QC reports Raw materials testing Product inspection

12. PCI-Certified Quality The advantages of PCI certification include: • Prequalified bidders • Expanded design options • Lower costs • Faster erection • Reliability • No added cost

13. PCI-Certified Quality Many organizations and government agencies either mandate or recommend PCI plant certification: • AIA Masterspec • Federal Aviation Administration • Bureau of Reclamation, • U.S. Dept. of the Interior • Federal Bureau of Prisons • Federal Highway Administration • U.S. Army Corps of Engineers • U.S. Veteran Affairs • U.S. Department of the Navy • General Services Administration • 30+ State Departments of Transportation

14. Safety and Security A precast structure can increase the safety and security of its occupants: • Fire Resistance • Earthquake Resistance • Vermin Resistance • Blast/Wind Resistance

15. Safety & Security: Fire Resistance Precast concrete offers superior fire resistance Senior housing and assisted living

16. Safety & Security: Fire Resistance Fire Safety: A Balanced Design • Containment • Detection • Suppression • Education

17. Safety & Security: Fire Resistance Precast structures can… • provide up to a 4-hour fire rating • reduce costs of meeting fire-rating requirements • reduce extent of fire damage and cost of repair

18. Safety & Security: Fire Resistance Insurance Cost Comparison* Insurers have noticed the fire-resisting advantages precast concrete offers these structures. A recent study at the University of Michigan found that the added cost of building with concrete and masonry was offset quickly by significantly reduced insurance costs. These expenses grow over time as annual premiums mount. Concrete &Masonry WoodFrame Construction Cost Annual Insurance Cost Insurance CostPer Unit $960,000 13,210 550 $1,033,000 1,429 59 Building cost difference: $43,000 Annual insurance cost difference: $11,781 The table shows typical ISO simplified fire class rates effective 1989. These rates are 80% coinsurance and are per $100 of insurance per year. The rates assume concrete block bearing walls, hollowcore plank floors and roof with a fire resistive rating of not less than one hour. *University of Michigan study

19. Safety & Security: Earthquake Resistance When building in a seismic zone you can take advantage of precast’s… • panelized systems • new connection techniques

20. Safety & Security: Earthquake Resistance PRESSS Research Project The Paramount, San Francisco, CA

21. Safety & Security: Vermin Resistance Precast is resistant to vermin such as: • Termites, carpenter ants and similar insects • Rodents

22. Safety & Security: Blast/Wind Resistance Precast is resistant to: • Blasts/explosions • Wind and wind projectiles

23. Sustainability Precast concrete is a sustainable material: • Minimizes energy use • Decreases site disturbance • Uses local, recycled materials • Can be recycled • Requires low maintenance, fewer chemicals • Improves indoor air quality • Helps meet LEEDTM certification (up to 27 pts.)

24. Sustainability Creating insulated wall panels

25. Layout Flexibility Precast concrete components provide layout and structural flexibility: • Long spans permitted by hollowcore and hybrid precast flooring systems • Load-bearing capacities of wall panel systems • Space-saving thin cross-sections

26. Low Maintenance Precast concrete requires very little maintenance: • Caulking every 15 to 20 years • Fewer joints — less moisture penetration

27. Acoustical Control Precast concrete offers: • Acoustical control (STC ratings of up to 50) • “Solid feel” with less vibration

28. Mold Resistance Precast resists mold growth • Inorganic material • Fewer joints — less moisture penetration

29. Controlled Environments Precast is especially suited for structures that require extreme cleanliness because it: • Resists mildew and bacteria • Withstands harsh chemicals • Provides air tightness

30. Expansion Capabilities Precast allows for expansion: • Adding new adjoining space • Merging a new space with existing structure • Adding second levels onto existing roof

31. Economy Precast concrete is economical: • Initial costs • Lower contractor costs • Shorter financing periods • Lower material costs • Life-cycle costs • Lower energy use • Smaller HVAC equipment • Lower insurance costs

32. Economy Keys to economical use of precast: • Repetition in fabrication • Efficient delivery • Efficient installation

33. Precast Housing Applications • Hotels/Motels • Single-Family • Multi-Family • Retirement Housing • Assisted Living • Student Housing

34. Precast Housing Applications: Hotels Hotels and motels made of precast or prestressed concrete can meet the needs of both the owners and customers. • Attractive appearance • Fire resistance • Moisture resistance • Acoustic control • Durability • Long clear spans • Structural support • Quick construction

35. Precast Housing Applications: Hotels Hilton Garden Inn Comfort Suites

36. Precast Housing Applications: Single Family For single-family homes, precast/prestressed concrete benefits designers, builders and owners: • Design flexibility allows the home to match the flavor of an existing neighborhood • Fire resistance • Long spans eliminate supporting beams and open up spaces • All-weather installation ensures schedules can be met • Monolithic production that eliminates entry points for moisture in foundations and facades

37. Precast Housing Applications: Single Family Precast hollowcore plank at first floor

38. Precast Housing Applications: Single Family Finished residence with precast plank at first floor

39. Precast Housing Applications: Multi-family Precast or prestressed concrete multi-family housing structures can satisfy needs of both designers and tenants. • Attractive exteriors that fit into surrounding neighborhood • Durability • Easy maintenance • Acoustic control • Minimize floor-to-floor heights and maximize number of levels • Fire resistance • Secure balconies • Quick construction Breakers Condos

40. Precast Housing Applications: Multi-family 3-Family Partnership Homes

41. Precast Housing Applications: Multi-family Precast concrete two-family housing

42. Precast Housing Applications: Retirement Retirement facilities present many of the same design challenges as multi-family housing—challenges that are easily met by precast or prestressed concrete. • Attractive exteriors that fit into surrounding neighborhood • Fire resistance • Low maintenance • Acoustic control, and • Quick construction to provide faster occupancy Orchard Park Senior Housing

43. Precast Housing Applications: Assisted Living As our population ages, more retirees are looking for a comfortable housing situation that meets all their needs. In some cases, these options allow additional medical services to be provided in another portion of the building within the same facility.  Precast/prestressed concrete offers key advantages in these facilities, including: • Fire resistance • Acoustic control, and • Economic construction that helps contain long-term financial costs for residents Prospect Heights

44. Precast Housing Applications: Student Housing Transitory students can be rambunctious, but they also require privacy for studying. Precast/prestressed concrete structures offer key benefits: • Durability • Acoustic control • Fast erection, which can ensure facilities are ready when students arrive • Design flexibility, allowing the residence to blend with existing campus structures of any type Curry College

45. Precast Housing Applications: Student Housing Renssalear Polytechnic Hall

46. Precast Housing Applications: Student Housing Residence Hall: Ithica College

47. Precast Housing Applications: Modular Housing Precast modules offer great opportunities for adding onto existing buildings or for creating projects with fast-track solutions in college dormitories, hotels and other housing structures. Precast concrete modular hotel room

48. Precast Housing Applications: Modular Housing The modules can be delivered with some attached furnishings, such as bathroom fixtures, already in place. Furnishings can be added quickly to create a durable, fire-resistant, acoustically controlled room. Module interior

49. Early Precaster Involvement The precaster can provide: • Technical advice • Engineering support • Aesthetic guidance • Economical solutions and product suggestions

50. Precast Housing Design Considerations • Exterior Finish • Interior Finish • Wall Panels • Floor/Roof Systems • Home Utility Systems