CarbonCast

1

• CarbonCast
• Architectural Panels
• Ken Baur, PE
• High Concrete Group

866.GO-ALTUS . www.altusprecast.com
PO Box 10097 Lancaster, PA 17605-0097
2
Contents

• Benefits Relative Cost
• Example Projects
• Details
• C-GRID Used
• Manufacturing Process
• Tests
• Ongoing Research Testing

3
Benefits Relative Cost

• CUSTOMER BENEFITS
• All the benefits of precast
• Up to 66 lighter
• Less concrete
• Larger pieces
• Reduced shipping
• Reduced erection time or crane size
• Ideal for use with a tower crane where capacities
  are limited
• Ideal for mid-and high-rise buildings or sites
  with poor soils
• Non-corrosive face reinforcing
• Ideal for salt-laden environments
• High Thermal Efficiency
• Composite R-values ranging from R-8 to R-12
• Superior mold resistance
• RELATIVE COST
• Installed cost of panels is same as -- or less
  than conventional precast
• Superstructure and foundation costs are usually
  less
• Insulation and/or HVAC costs can also be reduced

4
Benefits Relative Cost

• PRECASTER BENEFITS
• Can cost less to provide
• Less concrete
• Larger pieces
• Reduced shipping
• Reduced erection time or crane size
• Ideal for use with a tower crane where capacities
  are limited
• Ideal for mid-and high-rise buildings or sites
  with poor soils
• Unique, specifiable, proprietary
• Something new to talk about
• Gets you first and last look
• Hard to displace once its designed in
• Alternatives are less desirable
• Brick leaks, EIFS has problems, GFRC is not
  readily available and SlenderWall-like systems do
  not offer the same appearance or insulation
• Can be combined with conventional precast to
  value-engineer a job
• Precast spandrels on lower-story parking
• CarbonCast panels on upper stories

5
Example Costs/SF 8x30x6

• Conventional 75 psf
• - Engineering
• - Forming
• 3.37 - Sub-Total
• 1.42 - Strand/Rebar
• 2.10 - Connectors
• 1.00- Concrete (back)
• 1.24 - Concrete (face)
• .15 - CNI
• .45 - Mesh
• 6.00 - LO
• .76 - Permits
• 1.36 - Hauling
• 5.00 - Erection
• 20.75 - TOTAL

• CarbonCast 30 psf
• - Engineering
• - Forming
• 3.37 - Sub-Total
• .63 - Strand/Rebar
• 1.62 - Connectors
• .25 - Concrete (back)
• .93 - Concrete (face)
• .60 4 Foam
• .95 - C-GRID
• 6.00 - LO
• .38 - Permits
• .68 - Hauling
• 4.50 - Erection
• 19.91 - TOTAL
• Includes shear grid
• Excludes Savings On
• Foundations
• Superstructure

6
Shipping
7
C-GRID Enabling Technology
ACI minimum cover for steel reinforcing
In-use thicknesses begin at 4 and are usually 6
or more
.
.
5/8
1-5/8
3/4
Exterior face
Minimum cover for carbon fiber reinforcing
1/4
In-use thicknesses begin at 1 ¼
_
_
5/8
1/4
Exterior face
8
C-GRID Used
GIRD TYPES C 5500 FX C 5500 OX C 5500 Shear
Grid NOTE The grid we started with costs
1.15/sf. We are now testing grid that costs
.60/sf.
9
Example Projects

• MillionAir Terminal -- Teeterboro, NJ
• Executive terminal with 7,000 sf of cladding
• Heldrich Plaza New Brunswick, NJ
• 10-story mixed-use project (hotel and high-end
  residential) with 40,000 sf of cladding
• Symphony House Philadelphia, PA
• 31-story condominium with 120,000 sf of cladding

10
Recent Construction Shots
11
Heldrich Plaza
12
Heldrich Plaza
13
Architectural Panel Types

Panels can have any precast finish from
acid-etched to thin brick
14
Details
Prestressing or post-tensioning is required for
long or tall panels
15
Architectural Panel - Back Ribs
16
Architectural Panel - Horizontal Rib
17
Architectural Panel - Openings
18
Architectural Panel - Secondary Vertical Rib
19
Architectural Panel - Thin Brick Veneer
20
Architectural Panel - Horizontal Ribs
21
Architectural Panel Panel-to-Panel Firestop
22
Architectural Panel Solid Rib Firestop
23
Architectural Panel Assembly Firestop
24
Architectural Panel - Assemblies A B
25
Shop Details
Connections are the same as conventional
precast Hardware must be the same from precaster
to precaster
26
Thermal Efficiency
8-0 x 30-0 w/o thermally-broken top bottom
ribs
8-0 x 30-0 8 x 30 w thermally-broken top
bottom ribs
27
Manufacturing Process Sample Panel
28
Manufacturing Process
29
Other Manufacturing Examples
30
Tests

• Flexural Strength of Thin-faced Architectural
  Panels
• 2-0 x 8-0 x 1.25 Thick Slabs
• Lehigh University ATLSS Center Bethlehem, PA
• Wind Load Test 110mph
• 86x30-0x6 Architectural Panel
• Architectural Testing, Inc. York, PA
• Rilem Tube Moisture Absorption
• Test
• 1.25 Thick Samples
• Mark Patton, PE, Ph.D Pittsburgh, PA
• Thermal Cycling Test
• 86x30-0x6 Architectural Panel
• Mark Patton, PE, Ph.D
• Carnegie Mellon University,
• Pittsburgh, PA

1 thick panel supports car
31
Tests

• Prestressing of C-GRID for use in Architectural
  Panels - I
• Penn State University State College, PA
• One-hour ASTM E119 Fire Test
• Omega Testing Labs San Antonio, TX

32
Full-Scale Testing
33
Ongoing Research Testing

• Prestressing of C-GRID for use in Architectural
  Panels - II
• Lehigh University ATLSS Bethlehem, PA
• Pull-out of Inserts Lifting Devices in
  Thin-ribbed Members
• Lehigh University ATLSS Center Bethlehem, PA
• Missile Impact Test TAS 201-94
• Clemson University Clemson, SC
• Strand Bond Behavior in SCC
• Kansas State University Manhattan, KS
• Fire Performance of Intumescent Paints on
  Skim-coated EPS Foam
• Cost-reduction and development of a non-insulated
  panel

34
Technical Standards
35
Technical Standards

• General Technical Standard
• Technical Manual for CarbonCast Architectural
  Panels
• Technical Manual for CarbonCast Insulated Wall
  Panels
• Technical Manual for Double Tees

36
General Technical Standard

• Table of Contents
• 1. Use of C-GRID in Precast Products
• 2. Design Philosophy
• 3. Material Properties
• 4. Design Properties
• 5. Basic Design Requirements
• Design for Flexure
• Serviceability
• Creep Rupture and Fatigue
• Shear
• Temperature and Shrinkage
• Development and Splices
• 6. Design for Shear Transfer in Composite
  Action
• References
• Appendix A Shear Deformation

37
IWP Technical Standard

• Product Champion Harry Gleich
• TABLE OF CONTENTS
• 1 INTRODUCTION
• 2 GENERAL CONSIDERATIONS
• 3 FLEXURAL DESIGN
• 4 LOAD BEARING DESIGN
• 5 SHEAR WALL CONSIDERATIONS
• 6 DETAILING CONSIDERATIONS
• 7 INSULATION AND THERMAL PERFORMANCE
• 8 MANUFACTURE OF SANDWICH PANELS
• 9 PRODUCT TOLERANCES, CRACKING AND REPAIRS
• 10 HANDLING, SHIPPING AND STORAGE OF SANDWICH
  PANELS
• 11 ERECTION OF SANDWICH PANELS
• 12 INSPECTION OF SANDWICH PANELS
• 13 REFERENCE DOCUMENTS

38
Architectural Technical Manual

• Introduction
• Notation
• Chapter 1 CarbonCast Architectural Panels
• Chapter 2 Design of CarbonCast Architectural
  Panels
• Chapter 3 - Design of Connections for Gravity and
  Wind Loads
• Chapter 4 Production of CarbonCast
  Architectural Panels
• Chapter 5 Fire Resistance of CarbonCast
  Architectural Panels
• Chapter 6 Insulation Properties
• Chapter 7 Details
• Chapter 8 Guide Specification

39
Double Tee Standard

• Table of Contents
• INTRODUCTION
• Notation
• Chapter 1 CarbonCast Double Tees
• 1.1 General
• 1.2 C-Grid
• 1.3 Advantages of CarbonCast Double Tees
• 1.4 Design Responsibility
• Chapter 2 Design of CarbonCast Tees
• 2.1 General
• 2.2 IBC2003 Loading
• 2.3 Design Example
• Chapter 3 Connections
• 3.1 General
• Chapter 4 Production of CarbonCast Tees
• 4.1 General
• 4.2 Fabrication
• 4.3 Curing/Stripping
• 4.4 Finishing

40
Current Initiatives

• Refining Design of Architectural Panels
• Stem Decks Housing Wall Panels
• Double Tees
• Finalizing Technical Standards
• Moisture and Thermal Issues
• Fatigue and Sustained loading
• Code Issues
• Shear Capacity
• Minimum Reinforcement

41
Design Standards
42

• CarbonCast
• Insulated Wall Panels

866.GO-ALTUS . www.altusprecast.com
PO Box 10097 Lancaster, PA 17605-0097
43
Contents

• Testing
• Manufacturing
• Thermal Performance
• Competitive Comparison
• Details
• Projects
• Conclusions

44
Wall PanelsBenefits, Design Production

• Benefits of CarbonCast Wall Panels
• Example Projects
• Panel configurations and terminology
• Calculating R-values
• Standard and design examples
• Production process and photos
• Cost comparison vs. other systems
• Foams EPS, XPS Polyiso
• Summary of testing completed and in progress

45
CarbonCast Sandwich Wall
46
Full-Scale Load Testing

• Panel size ? 8-0 x 36- 0
• Panel configuration ? 2/ 4/ 2
• Prestressed

47
Load Test Details

• Panel cast in Greenville, SC
• Shipped to Oldcastle plant in RI
• Tested in 4-point bending
• Design load was 24 psf

48
Full-Scale Load Test

49
Test Procedure

• Loading Protocol
• 50 of designed wind in each direction 300
  cycles
• 85 of design wind load sustained for one hour in
  each direction
• Incrementally loaded to failure

This type of testing has never been done on an
insulated sandwich wall before!
50
Test Results
Testing showed that the CarbonCast insulated wall
panel is 100 composite!

• What does this mean?
• AltusGroup can make thinner panels because both
  wythes work together
• AltusGroup can span longer with thinner panels
• Panels are thermally efficient
• AltusGroup can supply panels with extremely high
  R-Values

51
Manufacturing
52
Lifting and Rotating Panel
53
Thermal Performance

• 1. AltusGroup insulated wall panel is as
  thermally efficient as any wall system in the
  market place.
• We use Expanded Polystyrene (EPS)
• Extruded Polystyrene (XPS) can be used but costs
  more

54
R-Values
55
AltusGroup vs. Competition
Lets Use a Sample Project to Compare AltusGroup
Panels with the DOW or Owens Corning Systems

• Case Study Project Parameters
• Height of building is 32 ft with roof tie point
  at 2 ft. from top of panel
• Load bearing for steel roof with bar joist span
  of 60 ft.
• R- Value required for this project is 13 --
  steady state

56
AltusGroup vs. Competition

• The AltusGroup Panel would be our Standard 8
  panel
• The Dow or Owens Corning Panel as non-composite
  panel would have a 2 outside wythe, 2.5 of
  insulation, and depending on the engineer, a 5
  to 8 inside wythe

57
AltusGroup vs. Competition

• Assume Costs
• Concrete 0.30/inch/ sq. ft.
• EPS insulation 0.12/in/sq.ft.
• Shear grid 0.32/sq.ft. wall surface
• Owens Corning system (w/ pins) 1.40/sq.ft. of
  wall surface
• DOW System (w/ non-composite pins) 1.40/sq.ft.
  of wall surface

58
AltusGroup vs. Competition

• AltusGroup Panel
• Concrete cost 0.30 x 4.67 1.41
• Insulation cost .12 x 3.33 0.40
• Shear Grid cost 0.32
• Total cost of material 2.13

59
AltusGroup vs. Competition
DOW Panel Concrete cost 0.30 x 7
2.10 Insulation cost 0.12 x 3.33
1.40 Total cost of material (minimum) 3.50
Owens Corning Panel Concrete cost 0.30 x 7
2.10 Insulation cost 0.12 x 3.33
1.40 Total cost of material (minimum) 3.50
60
AltusGroup vs. Competition
Comparison of Panel Weights AltusGroup panel
weighs 59 psf (22,700 lbs for a 12 wide x 32
tall panel) DOW or Owens Corning panel weighs
87.5 psf (33,600 lbs for a 12 wide x 32 tall
panel)
More panels/load!
61
CarbonCast Wall Panel Details
62
CarbonCast Wall Panel Details
63
CarbonCast Wall Panel Details
64
Sample CarbonCast Projects
65
Sample CarbonCast Projects
66
Conclusions

• High R-values for less cost
• 2 hour design
• Lighter weight panels
• 100 composite action leads to thinner panels,
  reduced construction costs, and more net rentable
  or usable floor area
• Horizontally-spanning hardwall panels can
  eliminate column-to-column foundations on
  pre-engineered buildings

67

• CarbonCast Pre-topped Double Tees
• Ken Baur, PE
• High Concrete Group

866.GO-ALTUS . www.altusprecast.com
PO Box 10097 Lancaster, PA 17605-0097
68
Contents

• Benefits Relative Cost
• Example Projects
• Enabling Technology
• Details
• Manufacturing Process
• Tests
• Ongoing Research

69
Benefits Relative Cost

• BENEFITS
• Superior flange durability
• Ideal for salt-laden environments
• Seaside locations
• First floor roof decks in the Northeast,
  Mid-Atlantic, Ohio Valley Midwest states
• 12 Lighter (if using one-hour rated 3 ¼
  flange)Reduction or elimination of
• Corrosion Inhibitors
• Epoxy-coated Mesh
• Post-applied Sealants - initial future
  applications
• RELATIVE COST
• Same as -- or slightly more than --
  steel-reinforced

70
Example Costs/SF 12TT

• Conventional 4
• - Engineering
• - Forming
• - Strand
• - Connectors
• - LO
• - Permits
• - Hauling
• - Erection
• 8.02 - Sub-Total
• .22 - Steel Mesh
• .21 - Epoxy or CNI
• 2.30 - Concrete
• 10.75 - Sub-Total
• .50 - Field Sealant
• 11.25 - TOTAL

• CarbonCast 3 1/4
• - Engineering
• - Forming
• - Strand
• - Connectors
• - LO
• - Permits
• - Hauling
• - Erection
• 8.12 - Sub-Total
• .60 - C-GRID
• .00 - Epoxy or CNI
• 2.05 - Concrete
• 10.75 - Sub-Total
• .00 - Field Sealant
• 10.75 - TOTAL
• Excludes Savings On
• Foundations

71
Example Projects

• GE Parking Deck Milwaukee, Wisconsin
• 90,000 sf installed on roof deck of 360,000 sf
  garage
• Channel Club Parking Garage Monmouth Co., NJ
• 90,000 sf to-be-built deck to replace badly
  deteriorated CIP garage

72
C-GRID Enabling Technology
ACI minimum cover for steel reinforcing
In-use thicknesses begin at 4
.
.
5/8
1-5/8
3/4
Exterior face
Minimum cover for carbon fiber reinforcing
1/4
In-use thicknesses begin at 1 ¼
_
_
5/8
1/4
Exterior face
73
C-GRID Used
GRID TYPES C 5500 FX C- 5500 - EX
74
Double Tee Narrow Leg

Design is Straight-forward per AltusGroup Design
Handbook
75
Double Tee - Wide Leg

76
Double Tee - Stem Blockout
77
Details
Max Span
Flange Thickness
Overall Depth
3 ¼ 4 5/8
Common spans and depths are used
26
62
3 ¼ 4 5/8
66
30
3 ¼ 4 5/8
70
34
NOTE 3 ¼ flange 1 hour-rated 4 5/8 flange
2 hour-rated
Assumes 50psf Live Load
78
Details
Vector connectors are required and should be
stainless steel
79
Manufacturing Process
80
Manufacturing Process
81
Manufacturing Process New Method
82
Manufacturing Process New Method
83
AltusGroup IMPRESSOR
84
Tests

• Uniform Concentrated Load Testing 4 Flange
• 3000 point load per IBC 2003
• Uniform live load per IBC 2003
• JWPeters Burlington, WI Rochelle, IL
• Washington University St Louis, MO
• Uniform Concentrated Load Testing 3 ¼ Flange
• 3000 point load per IBC 2003
• Exceeded requirements by 2x
• w/o cracking or excessive deflection
• Uniform live load per IBC 2003
• High Concrete Denver, PA
• Penn State Univ Harrisburg, PA
• One-hour E119 Fire Test
• 3 ¼ Flange
• Pre-cracked, joint at center, unrestrained
• Southwest Research Labs San Antonio, TX

85
Ongoing Research

• Cyclic load testing of C-GRID in double tee
  flange specimens
• Washington University, St. Louis
• C-GRID radiant heating applications
• TechFab, LLC Anderson, SC
• Prestressing of C-GRID for use in Architectural
  Panels - II
• Lehigh University ATLSS Bethlehem, PA

86

• Lightweight CarbonCast Architectural Panels
• When to Recommend Use

866.GO-ALTUS . www.altusprecast.com
PO Box 10097 Lancaster, PA 17605-0097
87
When to Recommend Lightweight CarbonCast Panels

• When deep window recesses, reveals or the
  appearance of thick panels is desired
• For high rises and mid-rises above 7 stories
• For salt-laden environments
• In high seismic or poor soil zones
• For recladding projects
• For LEED-certifiable buildings
• In Design Development
• Before the foundation and superstructure are
  designed
• Before a tower crane is selected
• In Value Engineering
• When the foundation superstructure can be
  rethought
• When the tower crane can be rethought
• When the theres a long crane reach required
• When the cost/pick is extremely high
• When site access is limited in hours
• When the project is a long way from your plant
• When you want to develop a proprietary spec

88
Lightweight CarbonCast Panels - Customer Benefits

• Enables more points toward certification than
  conventional precast
• Can improve wall assembly R-value and reduce
  HVAC/utility costs
• Can provide integral insulation and a smaller
  footprint or more net rentable/useable floor
  space
• Reduces opportunity for in-wall condensation
• Lighter weight works in many applications where
  precast doesnt and provides a superior result
  to other lightweight cladding options
• Reduces foundation, superstructure tower crane
  costs
• Reduces erection time
• Enables thick panels when they otherwise cant be
  afforded
• Provides a face that wont stain or spall

89
Lightweight CarbonCast Panels - Precaster
Benefits

• Provides a competitive performance advantage
• Provides access to work you wouldnt ordinarily
  get
• Provides competitive advantage on cost of project
• Can reduce the number of trucks required to
  service the job
• Can provide access to work you wouldnt
  ordinarily get
• Provides an opportunity to be competitive on jobs
  that are far away
• Limits the number of bidders to a select few who
  can do a good job

90
When to Recommend CarbonCast Architectural Panels
91
When to Recommend CarbonCast Architectural Panels
92
When to Recommend CarbonCast Architectural Panels
93
When to Recommend CarbonCast Architectural Panels
94
When to Recommend CarbonCast Architectural Panels
95
Benefits

• Fewer pilings
• Smaller spread footers
• Fewer perimeter columns
• Less load on slabs less slab reinforcing
  required for gravity loads
• Smaller/shorter shear walls w/lesser or fewer
  connections
• Lighter gravity connections
• Larger panels
• Thinner stud walls
• Less or no additional insulation

96

• High Performance CarbonCast Wall Panels
• When to Recommend Use

866.GO-ALTUS . www.altusprecast.com
PO Box 10097 Lancaster, PA 17605-0097
97
When to Recommend High Performance CarbonCast
Wall Panels

• When thermally-efficient panels are needed
• When a high R value is needed
• When Thermomass panels are being considered
• In lieu of block and brick
• When a load-bearing exterior wall is needed or
  when an opportunity to eliminate perimeter
  structure exists
• When a precast interior finish is desirable
• When a 2-3 hour fire rating is required
• When reducing the thickness of the perimeter wall
  is desirable
• For low and mid-rise buildings
• For salt-laden environments
• In high seismic or poor soil zones
• For LEED-certifiable buildings
• In Design Development
• Before the foundation and superstructure are
  designed
• In Value Engineering
• When the foundation superstructure can be
  rethought
• When the field construction schedule is
  constrained
• When theres a long crane reach required
• When the project is a long way from your plant

98
CarbonCast High Performance Wall Panels -
Customer Benefits

• Enables more points toward certification than
  conventional precast
• Can improve wall assembly R-value and reduce
  HVAC/utility costs
• Can provide integral insulation and a smaller
  footprint or more net rentable/useable floor
  space
• Eliminates opportunity for in-wall condensation
• Reduces foundation, superstructure tower crane
  costs
• Reduces construction time vs. other systems
• Can provide a face that wont stain or spall

99
High Performance CarbonCast Wall Panels -
Precaster Benefits

• Provides a competitive performance advantage
• Provides competitive advantage on cost of project
• Can reduce the number of trucks required to
  service the job
• Provides an opportunity to be competitive on jobs
  that are far away
• Limits the number of bidders to a select few who
  can do a good job

100

• CarbonCast Pretopped Double Tees
• When to Recommend Use

866.GO-ALTUS . www.altusprecast.com
PO Box 10097 Lancaster, PA 17605-0097
101
When to Recommend CarbonCast Pretopped Double Tees

• When a pretopped deck is desired
• When pourstrips can be eliminated
• When eliminating maintenance is desireable
• In salt-laden environments
• 1-2 hour fire rating is required
• When reducing the weight of the tee is is
  desirable
• In high seismic or poor soil zones
• For LEED-certifiable buildings
• In Design Development
• Before the foundation and superstructure are
  designed
• In Value Engineering
• When the foundation superstructure can be
  rethought
• When the field construction schedule is
  constrained
• When theres a long crane reach required
• When you want to develop a proprietary spec

102
CarbonCast Pretopped Double Tees Customer
Benefits

• Enables more points toward certification than
  conventional precast
• Reduces foundation superstructure costs
• Provides a longer-lasting flange that needs less
  maintenance

103
CarbonCast Pretopped Double Tees Precaster
Benefits

• Provides a competitive performance advantage
• Provides competitive advantage on cost of project
• Limits the number of bidders to a select few who
  can do a good job