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TOTAL PRECAST SYSTEMS DESIGN GUIDE
2007/2008 EDITION
Total Precast Systems Design Guide
TABLE OF CONTENTS
Eric Taylor Photography.
Purpose and Mission Statement Through mutual education and understanding, we help grow one anothers success. As stated in our Partner of Choice Commitment, The Shockey Companies are dedicated to serving as teachers and learners. It is in that spirit that The Shockey Precast Group partnered with Hayes, Seay, Mattern & Mattern, Inc. (HSMM) to create the 2007 Total Precast Systems Design Guide. This unique reference document is structured to provide a broad range of information about total precast systems as a viable construction method, and to be utilized as a design guide by architects, owners, and general contractors. It is provided with the understanding that this document and the information contained herein should not be used without rst securing competent advice with respect to its suitability for any general or specic application. The 2007/2008 Shockey Total Precast Systems Design Guide includes chapters on Features & Benets, Building Envelope, Design Considerations, Components & Connections, LEED, Case Studies, and Shockeys load-bearing architectural guide specication. We hope that this guide will give you a thorough understanding of the capabilities and benets of total precast systems; and that it serves as a source of inspiration for your future designs. Total precast systems represent the new direction of the construction industry, especially as increased emphasis is placed on aggressive schedules, leaner budgets, and structures that are aesthetically intriguing while being practical and functional. The versatility, cost effectiveness, and exibility of total precast make it a superior building system for a wide range of design applications. For these reasons, The Shockey Precast Group is proud of its continued efforts to advance the utilization of total precast systems. The Shockey Companies and Hayes, Seay, Mattern & Mattern, Inc. make no warranty, guarantee, or representation as to the accuracy or sufciency of the information provided herein, and neither assumes any responsibility or liability regarding the use or misuse of such information.
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Introduction
Features and Benets Historical Perspective
The Building Envelope

Typical TPS Applications Featured Applications Architectural Features
DesignConsiderations Considerations Design

Architectural Structural MEP
2007 SHOCKEY PRECAST GROUP . ALL RIGHTS RESERVED.
Components & Connections

Typical Components Typical Connections Coordination with Other Trades
LEED Considerations
LEED Criteria Points Scoring Example
Recent Case Studies

Total Total Precast Systems Specication
Frederick County Public Safety Building Highmark Data Center Precast Systems Speci cation Stoneleigh at Westelds Ofce Buildings
TPS Guide Specication

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Glossary
The Shockey Precast Group 219 Stine Lane Winchester, VA 22604 540-667-7700 www.shockeyprecast.com
Front cover photo: Stoneleigh at Westelds Ofce Buildings Left: Frederick County Public Safety Building Erection, Stairs. Below: The Frederick County Public Safety Building showcases how the successful marriage of structural precast components with architectural precast features creates the unique building method known as total precast systems. Contents page: Stoneleigh at Westelds, Ofce Buildings I and II
INTRODUCTION
In this chapter, well explore the many benets total precast systems offer to owners, architects, and general contractors. Well also discuss the emergence of total precast from an overall industry perspective, and its evolution as part of The Shockey Precast Groups history.
Features and Benets

A crew of 11-12 workers can easily erect 12-14 total precast components per day per crew. Quick erection times and smaller crews are just two of the benets of total precast that contribute to overall safer and cleaner jobsite.
Total precast systems seamlessly integrate the strength and integrity of structural precast with the visual style and aesthetics of architectural precast. The result is a unique building method that offers both common sense functionality and almost unlimited design possibilities. In both design and construction, total precast delivers signicant benets for owners, architects, engineers, and general contractors.
SPEED-TO-MARKET
The speed-to-market of total precast means faster delivery of the nished building, which can result in a signicant cost savings for the owner. Speed-to-market enables owners to begin leasing ofce space sooner, translating to a faster return on investment for the owner.
Below: Typical example of how Total Precast System creates openness.
FLEXIBILITY OF SPACE PLANNING

From a design perspective, the greatest advantage of a total precast system is the versatility and exibility of space planning options. Total precast delivers interior space unencumbered by a multitude of columns, allowing for greater freedom of design options. Using this system the trend for larger open oor plates is accommodated quite easily. Typical total precast column grid spacing is 50% greater or more than other framing systems. Room layouts are not encumbered by the structural elements. In short, architects and designers will have greater freedom to obtain the optimum ofce layout.
THE SHOCKEY PRECAST GROUP , WINCHESTER, VA WWW.SHOCKEYPRECAST.COM
INTRODUCTION
INTRODUCTION
Frederick County Public Safety Building - Interior Space Planning Layout
INTRODUCTION
INTRODUCTION
Frederick County Public Safety Building - Interior Space Planning Layout
INTRODUCTION
Erection of Stoneleigh at Westelds ofce building.

INTRODUCTION
CONSTRUCTION COSTS
For general contractors, total precast systems provide a safer, cleaner jobsite, faster access for follow-on trades, and an overall shorter construction schedule. A shorter construction schedule can greatly reduce the general contractors costs (General Conditions) of running the job, while increasing the availability of GC crews for other projects. In this way, total precast systems actually provide economic benet to the general contractor by freeing their resources to handle more work. Total precast construction allows more exibility in the General Contractors schedule than other construction methods, especially in the erection of precast. Precast can be erected at an average rate of 12 pieces per crane per day, and can be erected in weather conditions that would be problematic for the full erection of steel components. Total precast systems also offer the benet of requiring less site space for erection materials. As a result, total precast systems are a more exible construction choice for projects with a small site footprint or limited site access.
CONSTRUCTION COSTS COMPARATIVE ANALYSIS FREDERICK COUNTY PUBLIC SAFTEY BUILDING

The following analysis presents the costs associated with construction of the Frederick County Public Safety Building as a total precast structure compared with costs had the equivalent building been designed as a steel frame structure with architectural precast cladding, a cast-in-place structure with architectural precast cladding, or a brick masonry bearing structure with architectural precast cladding. As referenced in the schedule below, the use of total precast systems effectively reduced the overall general conditions by two (2) months.
INTRODUCTION
The following graph clearly illustrates the cost advantages and savings available to owners through the use of total precast systems versus more traditional construction methods such as steel framing, brick masonry, or cast-in-place frame. In the case of the Frederick County Public Safety Building, the total precast system was $278,000 less than the nearest competing system, and two months faster than the nearest competing system.
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INTRODUCTION
Historical Perspective
TOTAL PRECAST SYSTEMS
The history of total precast systems is not so much dened by specic projects, but rather by the evolution of markets in specic areas. Total precast systems have been around and utilized since the beginning of the precast industry in the mid 1930s. However, precast manufacturers in specic areas have embraced this construction concept and driven their market to relative levels of success and application by their sheer desire to prove the value and worth of total precast systems, as well as to satisfy their passion for constructing in this medium. The Denver, Colorado precast community, in particular, has readily and openly embraced total precast systems as a valuable and important construction method. Over a period of several decades, with extensive marketing, engineering, and architectural design support, as well as mentoring and research and development efforts, the concept of total precast systems became the construction method of choice for many ofce developments in the Denver area. Two excellent examples are the Denver Tech Center and Meridian Ofce Park. These projects both date back to the 1970s, and make extensive use of total precast as an economical and aesthetic value-based system choice. Over the next several decades, the use of total precast systems steadily gained acceptance and popularity in projects across the nation. While it seemingly took years to build these markets and prove the worth of total precast, the loss of specic people or companies signicantly curtailed the use of this construction method in the local markets. Total precast is not a system that can be built simply to promote the medium. Successful advancement within the construction industry is dependent upon a passionate and dedicated presence in the local precast community, both within precast companies as well as individuals. Today, total precast systems have gained widespread recognition for their versatility and economy. Total precast systems represent the future of construction as a building method that offers unparalleled value, cost and schedule savings, and exibility in aesthetic presentation.
THE SHOCKEY PRECAST GROUP , WINCHESTER, VA WWW.SHOCKEYPRECAST.COM INTRODUCTION 11
THE SHOCKEY STORY

In 1896, Howard Shockey opened a wagon-repair and general contracting business in Winchester, Virginia. His reputation for quality construction and do-it-right-therst-time attitude quickly put him in demand for custom home building. Today, many of the homes he built at the turn of the century still stand; monuments to his legacy of hard work, integrity, and Crider & Shockey company truck. dedication. Howard passed that legacy to his sons, and in the 1930s, Jim Shockey joined his father in the business. He was later followed by his brother Ralph. In 1947, the company became known as Howard Shockey and Sons. In 1943, Jim Shockey teamed up with his friend Jim Crider to create the rst rural ready-mixed concrete business west of the Blue Ridge Mountains. Known as Crider & Shockey, the company that started as the concrete division of Howard Shockey and Sons grew to include ten plants; and became a leader in furnishing ready-mixed concrete to the northern Shenandoah Valley region. With the birth of the precast/prestressed concrete industry in North America, the Shockey family was quick to recognize the numerous benets of precast concrete, and by 1955, had opened a small manufacturing facility for prestressed concrete as a division of Crider & Shockey. One year later, Shockey Brothers, Inc. became the third Shockey operating company. Now known as The Shockey Precast Group, the company specializes in structural, architectural, and total precast systems; and serves its customers in the Mid-Atlantic region from two manufacturing facilities in Winchester and Fredericksburg, Virginia.
Shockey Precast Group casting yard.

12 INTRODUCTION
Fairfax Judicial Center Parking Structure, Fairfax, VA
STRUCTURAL PRECAST SYSTEMS Parking Structures

Parking structures have always been the cornerstone of The Shockey Precast Groups structural business. To date, weve completed more than 300 parking structures throughout the MidAtlantic region. With an endless variety of nishes and features such as architectural thin-brick, our precast parking structures satisfy both the owners desire for functionality and the designers aesthetic vision. Some of The Shockey Precast Groups noteworthy parking structure projects include the Calvert St. parking structure in Annapolis, Maryland, Shady Grove Metro Station in Rockville, Maryland, The Winchester Medical Center parking structure in Winchester, VA and Fairfax Judicial Center parking structure in Fairfax, VA.
Shady Grove Metro Station, Rockville, MD
Calvert St. Parking Structure, Annapolis, MD
Largo Metro Station, Rockville, MD
The Winchester Medical Center Parking Structure is an excellent example of how the Shockey Precast Group seamlessly blends functionality with pleasing aesthetics.
INTRODUCTION 13
Shady Grove Metro Station Parking Structure, Rockville, Maryland

14 INTRODUCTION THE SHOCKEY PRECAST GROUP , WINCHESTER, VA WWW.SHOCKEYPRECAST.COM
The use of architectural precast components manufactured by the Shockey Precast Group gave a striking exterior to the 901 New York Avenue ofce building in Washington, D.C., pictured right.
ARCHITECTURAL PRECAST SYSTEMS

Prison Fellowship Ministries Headquarters, Loudon County, VA
Architectural Precast
Distinct and unique architectural features help to create a buildings individual signature. Whether classic, traditional, or modern, a buildings architectural style captures and reects its purpose, style, and character. The Shockey Precast Group has a history of working on some of the regions most impressive and visually striking buildings, including the 901 NY Avenue ofce building in Washington, D.C., John Paul Jones Arena at the University of Virginia, the First Mariner Bank Tower in Canton Crossing, Maryland, and the Prison Fellowship Ministries headquarters in Loudon County, Virginia.
First Mariner Bank Tower at Canton Crossing, Maryland
John Paul Jones Arena, University of Virginia, Charlottesville

INTRODUCTION 15
TOTAL PRECAST SYSTEMS

Through the years, the development of the precast industry evolved from purely structural applications such as bridges and parking structures to architectural features such as precast cladding appropriate for ofce buildings. As the almost-limitless design possibilities of architectural precast were realized in the construction industry, architectural precast systems became a means for designers to bring their architectural visions to life. The natural marriage of structural capability with architectural features and nishes created the unique system known as total precast. For The Shockey Precast Group, specialization in this building method owed naturally from its expertise and experience in structural and architectural precast systems. Tracor ofce building erection
SHOCKEY TPS HISTORY

In 1983, The Shockey Precast Group constructed the Tracor ofce building in Northern Virginia. The project was signicant because it signaled Shockeys entrance into the total precast systems industry. With the success of Tracor, industrial warehouse total precast projects such as Hershey Foods warehouse and Echostar Communications followed. For almost 25 years, the Shockey Precast Group has been the Partner of Choice on numerous total precast projects, including most recently the 2006 PCI Design Award-winning Highmark Data Center in Harrisburg, Pennsylvania, Stoneleigh at Westelds Ofce Buildings I and II in Chantilly, VA; Frederick County Public Safety Building in Winchester, VA, and Commonwealth OCX Data Center.
Tracor ofce building
The Tracor ofce building was SPGs rst total precast project.
16 INTRODUCTION THE SHOCKEY PRECAST GROUP , WINCHESTER, VA WWW.SHOCKEYPRECAST.COM
Echostar Communications uplink facility

Echostar Communications
Fredrick County Public Safety Building, Winchester, VA
Fredrick County Public Safety Building erection
Highmark Data Center, Harrisburg, PA

Highmark Data Center erection
Stoneleigh at Westelds, Chantilly, VA
Stoneleigh erection
INTRODUCTION
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INTRODUCTION
Eric Taylor Photography, 2006
THE BUILDING ENVELOPE

This chapter will provide a glimpse of the wide array of design possibilities offered through total precast. Featured projects will explore a sampling of building geometries, while Architectural Features references the palette of nishes and articulations that can be combined to satisfy even the most demanding designer.
Stoneleigh at Westelds Ofce Building One erection, 2006

Typical Total Precast Systems Applications:

Public Safety Building Mission Critical Data Center Class A Ofce Building Typical Mixed-Use Retail Total precast systems offer a myriad of structural design possibilities. Far more than the stereotypical gray box, the versatility of total precast lends itself well to a diverse range of design options. Following is a sampling of the total precast system possibilities available with Shockey. These designs do not represent the full extent of our capabilities, but illustrate the exibility of total precast in building geometry.
Stoneleigh at Westelds project wall panel
Rooftop view of completed Stoneleigh at Westelds Ofce Buildings One and Two
THE BUILDING ENVELOPE 19
Featured Applications
PUBLIC SAFETY BUILDING
This 61,500 SF county government building was constructed to house the Sheriff and Fire and Rescue Departments. It was designed to also include space for the Emergency Communications Center and Emergency Operations Center. A total of 287 precast components were used in the erection of this building, including 105 double tees, 10 columns, 6 stair modules, 32 cornice pieces, 118 wall panels, 10 beams, and 6 at slabs. The most challenging engineering design encountered for this project involved the analysis and design of two (2) precast header beams for the interior stair core. In order to accommodate bearing for stair risers, at slabs, and double tees, the cross-sectional geometry of these members changes several times along the length of the pieces; requiring rigorous analysis and detailing of reinforcement.
Erection starts.
Erection, phase 3.
Erection complete.
20 THE BUILDING ENVELOPE THE SHOCKEY PRECAST GROUP , WINCHESTER, VA WWW.SHOCKEYPRECAST.COM
Government Public Safety Building - 3D Building line view Modeling perspective showing precast panelization along frontage view. Double Tee roof and oor framing, interior supporting beam line with exterior load bearing wall panels.
Government Public Safety Building - Typical Ofce Roof Framing Plan Roof plan showing double tee layout framing with center line column and beam bearing.
THE SHOCKEY PRECAST GROUP , WINCHESTER, VA WWW.SHOCKEYPRECAST.COM THE BUILDING ENVELOPE 21
Government Public Safety Building - Elevation on Grid A, South Side
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MISSION CRITICAL DATA CENTER

This 317,000 SF industrial-use data center was constructed for a private corporate owner. A total of 1,366 precast components were utilized in the construction, including double tees, inverted T-beams, wall panels, stairs, insulated walls, and screen walls. The mission-critical nature of this building required that it be designed Seismic performance category C basic wind speed of 162 MPH, with a mechanical room oor live load of 150 PSF, and emergency generator rooms live load of 225 PSF.
Mission Critical Data Center - Typical Ofce Floor Framing Plan Floor plan illustrating double tee oor, beam, column and perimeter wall panel member placement.
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Mission Critical Data Center - West Exterior Along Grid G Elevation of wall panel layout and placement- (match line indicates building continuation).
Mission Critical Data Center - East Elevation Along grid A Building cross section showing double tee, beam and column framing members.
Mission Critical Data Center - Building Cross Section Along Grid 2 (top) and Building Cross Section Along Grid 4 (bottom) Building cross section showing double tee, beam and column framing members.
HIGHMARK DATA CENTER

This 82,000 SF, two-level precast building was constructed to house the ofces and computers for Highmark Blue Shield of Camp Hill, PA. The building was designed for a 150-psf live load plus 70 psf roof loads, and to withstand wind bursts of up to 110 MPH. The exterior of the building is a combination of multiple-depth sand blasted R-16 insulated precast wall panels and laid-up brick. 16 screen walls enclose an open courtyard around external mechanical equipment. Precast played an important role in the Leadership in Energy & Environmental Design (LEED) of the building. Use of slag in the precast concrete mix design provided 20% use of
Below left: Highmark West Elevation. Below right: Wall along column line 1.
recycled materials. The structures design allows for future expansion of the facility. The structure was erected in only 5 weeks, enabling the General Contractor to compress his overall schedule to meet the Owners move-in requirements.
Highmark Data Center - First Floor Framing Plan Floor framing plan illustrating double tee oor, beam, column and perimeter wall panel member placement. Area in layout shown as highlighted in small 3D reference model at lower right.
Highmark Data Center - Second Floor Framing Plan Floor framing plan illustrating double tee oor, beam, column and perimeter wall panel member placement. Area in layout shown as highlighted in small 3D reference model at lower right.
Below right: Typical roof/ oor framing plan. Below left: Typical inverted tee beam-tocolumn connection.
Highmark Data Center - Roof Floor Framing Plan Floor framing plan illustrating double tee oor, beam, column and perimeter wall panel member placement. Area in layout shown as highlighted in small 3D reference model at lower right.
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Highmark Data Center- North Elevation Building Elevation of wall panel layout and placement.
Highmark Data Center- East West Elevation. (Top)East Elevation along line F. (Bottom) West Elevation Along Line R. Building Elevation of wall panel layout and placement.
Below: Typical column to castin-place foundation, typical double tee bearing condition. Below right: Untopped double tee surface.
Highmark Data Center- North South Elevation. (Top)North Elevation along line 1. (Bottom) South Elevation along line 6. Building Elevation of wall panel layout and placement.
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CLASS A OFFICE BUILDING

This project consisted of two 221,000 SF mirror-image ofce buildings and a single elevated level, 59,000 SF precast parking garage constructed for an insurance company. Approximately 464 precast components were utilized for each ofce building, including columns, spandrels, 12 x 26 x 2 ange double tees, stair walls, elevator walls, and stairs. Approximately 195 precast components were utilized for the parking structure, including columns, spandrels, stair walls, stairs, shear walls, and 12 x 30 x 4 ange double tees. This represents The Shockey Precast Groups most recently completed total precast ofce building project.
Class A Ofce Building - Typical Ofce Floor Framing Plan Floor framing layout showing placement and span integrating three stairwell-elevator areas. Note center beam bearing line permitting long span column free areas.
Class A Ofce Building - West Elevation on Grid C
Class A Ofce Building - East Elevation on Grid A

Stoneleigh at Westelds East Elevation.

TYPICAL MIXED-USE RETAIL APPLICATION (HYBRID) SYSTEM

This 426,000 SF mixed-use retail building was constructed for Target Corporation. The building is comprised of three oors, at 142,000 SF per oor. A total of 929 precast components were utilized during construction, including anges, at slabs, walls, stairs, columns, beams, spandrels, and ramp walls. Shockey was presented with several special design considerations unique to the buildings retail purpose. 12 at slabs were used in the receiving area to allow for additional shelving spaces. A 3.5 to 5.5 topping slab acts as a diaphragm to transfer loads to the shear wall system. The architect utilized a composite topping with a waterproof membrane, drain board, and insulation sandwiched between a CIP topping and double-tee system. The composite system was rated for 2-hour re resistance. This project was unique because there was no need for a precast concrete roof structure. The roof on this project was constructed from steel; however, the remainder of the structure is precast concrete. The Shockey Precast Group erected the structural steel roof components concurrent with the precast by Shockey erection crews.
Mixed Use Retail - Building Elevation On Grid 1
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Mixed Use Retail - East Elevation On Grid F
Mixed Use Retail - First Floor Framing Plan

Mixed Use Retail - West Elevation On Grid F
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Architectural Features
Final design of the faade is an iterative process that begins with the sampling process and ends with mock-ups.
SAMPLING PROCESS
12 x 12 samples are an effective means for realizing the architects concepts into a production standard. Samples can include one or more colors, nishes, or different materials (such as brick or stone) cast into the precast. The varieties available are almost endless. These samples establish the basis for beginning the mock-up process and are the catalyst for other exterior selections such as glazing, window and door framing, and other exterior design features. Initial precast selections may be made using the Precast Concrete Institute (PCI) Architectural Color & Texture Guide, available through your Shockey Precast Group Sales representative. This Color & Texture Guide presents the vast array of colors, textures, and nishes available with precast concrete, and establishes a baseline guide for actual samples. Production samples may be obtained from a local PCI-certied producer. Selecting a sample from a producer close to the project site will demonstrate to the designer the range of available materials, as well as specic production capabilities and nish qualities. Locally produced precast may be more cost effective due to reduced material shipping costs both for the raw materials and nal delivery to the site.
After the project is awarded to the general contractor, a submittal sample should be obtained from the precast subcontractor. Like the production sample mentioned above, obtaining this sample from the precaster awarded the project is critical due to variations in individual plant preferences, differences in techniques, and sources of materials in the various plants, even within the same region. It should be noted that it may be difcult to obtain an exact match to the original production sample. Slight variations may exist in color, aggregate, or texture from the original sample. If specied, the architect may request multiple submittal samples to evaluate the nal sample selection. Obtaining an approved sample here is important as this will become the standard that the full scale panel mock-up will be judged against.
Mock-ups
Sample (4 x 4 or larger) mock-ups will be developed from the approved submittal sample to show the potential variations that may occur in a larger eld of exposure, and taking into account actual design proles. The mock-up process must be started early enough in the construction of the project to allow for the procurement of long lead time items such as thin brick and form liners, as well as time for precasting to obtain an approved mock-up. Total precast project mock-ups should specically be targeted to show the potential variations that may occur in high-prole or dual-purpose panels where the consolidation methods may vary due to panel function (cold pour vs. monolithic pour - see page 38). The type of applied nish to these articulations should be taken into account during this process in order to establish uniformity. Slight variations from the submittal sample may be expected but should be evaluated at
this phase to maintain the overall aesthetic quality. Creating mock-ups of all the precast shapes and congurations required on a project is usually not feasible, so key or highly visible elements should be selected by both the architect and precast manufacturer to nalize the nish selection. Plant visits during the casting process to view rst form casts should be an integral part of the process to ensure that the established criteria is maintained, as well as to view additional shapes not represented during the early mock-up phase. In cases where the faade has critical performance criteria such as blast protection, resistance to high wind-driven rain inltration, or aesthetics, the architect may specify and owner may authorize an additional expenditure for full-scale mock-up of a portion of the building exterior. This type of mock-up will usually incorporate all of the major building components such as windows, caulking, and other enclosure elements. In other circumstances where the performance criteria is more aesthetic, the mock up will serve to verify the overall design intent and remove any uncertainties the architect or owner may have regarding the sample. This additional approval step may then lead to design modications which could improve both the project appearance and performance. Sufcient time should be built into the project schedule to do the appropriate testing, incorporate changes, and obtain nal approvals before nal production begins.
The mock-up is an invaluable tool for verifying overall design intent and for establishing nal nishes.
Cold Pours vs. Monolithic Pours

Cold pours are required when precast either abuts another piece of precast in the same plane (parallel) or has a return exceeding approximately one foot (depending on the mix design) in order to ensure a nish that will match the control sample (cast face down in form). When cold pours are required it is highly recommended that a quirk be incorporated in the design to ensure the best aesthetic corner nish. Mono pours should only be used in situations where the adjacent precast is either perpendicular to the return, does not abut any other precast or is required for structural reasons. Since the return leg is cast vertically the migration of air during vibration, distribution of aggregates due to gravity and air voids do not allow for the same consolidation and appearance achieved when precast is cast at. In most cases this requires a post pour treatment to the vertically cast surfaces to bring them to an acceptable aesthetic level as long as they do not directly abut a parallel precast panel that was cast face down.
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Cold Pours
The reason that quirked corners are highly recommended to that of a 90 degree corners is due to the aesthetic end result based on the fabrication process. When cold pours are required the break of between pours is made in the corner to hide the transition. For 90 degree corners this creates a sharp corner during the fabrication process. The coarse aggregate (which helps provide the required strength) cannot ow into the sharp corner during the casting process. This allows a slurry mix of ne aggregates and cement paste to get through, creating the following two issues: 1. The extreme corner tends to have a color and appearance slightly different from the main body of the panel. 2. Due to the lack of coarse aggregates in the sharp edge, there is a higher probability of chipping and spalling of the outermost surface when standing the rst pour up on edge.
Detailed Section Through 90 degree Corner Cold Pour
Cold Pour Quirk - cold pour line is not visible on any exposed nish areas.
Step by Step Details on the Cold Pour Process

Thin Brick Veneer

One nish option to consider in the total precast system is thin brick veneer. This system can eliminate many of the drawbacks to conventional brick, which is typically eld labor intensive, weather sensitive, and time consuming. Conventional brick is also subject to water inltration. These limitations can be overcome when the desired aesthetic application of brick is married with precast to create a thin brick veneer. Nearly all colors, textures, and nishes available in hand-laid brick can also be found in thin brick veneers. When the pleasing visual appearance of traditional clay products is combined with the economy, versatility, and strength of precast, it provides numerous benets to construction utilizing total precast. Incorporation of thin brick into precast allows for stringent quality control methods to be implemented in a plant environment. Concrete batching systems and the curing environment are more tightly controlled, and utilizing clayfaced products in this method has the advantage of reducing eforescence, which is generally caused by water inltration.
THE BUILDING ENVELOPE 41
Typical column cover

In order to successfully marry these two products, the strict modular requirements of plant-cast precast are incorporated into the dimensionally loose tolerances of traditional hand-laid brick. Four main thin brick (TBX) suppliers support the dimensional controls required by PCI found in thin brick Type TBX of ASTM C1088. These manufacturers provide almost all of the styles, sizes and features available in traditional brick, including, but not limited to brick corners, edge corners, and three-sided corners, which provide the look and feel of hand-laid brick. Thin brick is designed specically to create an integral bond between the brick veneer and precast units. This occurs during fabrication of the clay modules by scoring and/ or creating dovetail slots on the rear to increase the bond capacity in both shear and tension. The bricks are secured into the form through the use of a rubber liner, plastic liner, or snap liner. Each type of liner has its own unique benets, and the decision to use a particular liner or combination of liners is based on specic applications. Brick veneer panels typically receive an acid rinse after being removed from the form. The acid rinse removes surface laitance from casting, and etches the precast joints between the brick, exposing the sand to mimic hand-laid brick mortar. Although thin brick is placed and cast in the concrete, it will retain some of the desirable mild imperfections found in hand-laid brick, and should be held to the same tolerance and standards outlined by the Brick Institute of America.
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Brick Bond Types and Joint Treatments for Thin Brick Almost any bond type and joint treatment that is available with hand-laid brick is available in the thin brick system including specialty and custom bond types. Clarity in designating the exact bond type desired is needed since some of the pattern types have slight variations of interpretation from region to region. Examples of some of the typical bond types available are noted below and are available with both a tooled joint and raked joint:
Flemish Bond
1/3 Running Bond
Running Bond
Stepped 1/3 Running Bond
Herringbone
Offset Weave
Soldier Course
Basket Weave
Thin Brick Application Depending on the color or type of thin brick selected, the appropriate liner best suited for that particular brick is utilized (i.e. elastomeric, plastic or snap grid). Once the full delivery of bricks are at the precast plant, they then need to be mixed throughout the shipments to insure that the desired variations in brick are evenly dispersed over the brick elds. Each brick is hand laid into the form to ensure a snug t to insure a good seal around its perimeter. Once this is complete they are now ready for the back-up facing mix which will provide the simulated grout joint color.
Common precast articulations include the following shapes and designs: Lintels Bull nose Cornice Reveals False joints Medallions Fins Projections Recesses Quirks
Articulations
Articulations express the design intent of the architect while adding life to the precast faade and establishing the unique character of the building. They provide visual interest for both close up and distant viewing. Flexibility and design freedom are the hallmarks of precast faade design. A key advantage for the designer is that precast can be formed to achieve almost any imaginable design and shape. No other building component system can rival this exibility. Applied nishes should always be considered when designing articulations in order to achieve the maximum aesthetic benets of precast. Applied nishes are surface treatments that are for the most part achieved after the precast panel has been cast and stripped from the form. This is done through a variety of techniques used to break or disrupt the outer paste layer of the precast surface and expose at various degrees either the ne or coarse aggregates utilized within the mix. Although specialized tools and equipment are used in this process, it still requires the specialized skills and eye of the precast nishing artisan to maintain a consistent pleasing nal nish.
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The use of precast articulations can greatly enhance a buildings individual style and character.
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Articulations are often incorporated into building designs to create a striking or dramatic faade.
Mix Designs
Mix design represents the proportions of cement, water, pigments, admixtures, ne and coarse aggregates. These base components comprise the initial sample selection. In a total precast system, a variety of mix designs may be utilized based on specic precast performance requirements. The requirements will vary depending on whether the precast component is structural or purely architectural in nature. Depending upon project design requirements, mix design proportions can be adjusted to meet project requirements averaging, but not limited to 5,000 -- 7,000 psi. This range far exceeds the 3,000 psi capabilities and performance of traditional cast-in-place concrete. Breakthroughs such as self consolidating concrete (SCC) have signicantly expanded precasts ability to meet the demands of even the most challenging designs. Advances in chemical technologies have also made it possible to incorporate specic materials, such as corrosion inhibitors, into the mix design when structures are placed in extremely harsh environments such as coastal areas. All of these considerations are taken into account during the formulation of nal mix designs. For architecturally exposed precast surfaces, it is highly recommended that the nal nish be achieved by utilizing only white cement. Gray cement has a higher percentage of variation during its manufacturing process that, even when mixed with white cement, can create objectionable changes in color or shade throughout the fabrication process. However, the use of gray cement in non-exposed areas is a key element in making precast an economically viable solution. The designer should note that increases in cost can result from changes to a mix design. A number of factors may inuence the cost increase. In general, local aggregates are preferable because they are less expensive. Gray cement is also more cost effective than white cement; however, it has more variations than white cement. This can be a critical consideration when trying to match color. In terms of pigments, earth colors such as buff and brown are typically less expensive than red and orange. Special colors, such as blue and green, are the most costly. The quantity of pigments will also impact cost, as will factors such as corrosion inhibitors, and changes to aggregate quantities to meet nish requirements. When specifying particular nishes, it is important for the designer to consider the overall cost increases associated with changes to established mix designs. The following pages include examples of the mix designs used on Frederick County Public Safety Building.
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Architectural Features
COLOR, TEXTURES AND APPLIED FINISHES
The use of color and textures in precast concrete gives the designer incomparable freedom. Through a variety of aggregates, choice of matrix colors, varying depths of exposure, and nishing techniques, precast can meet almost any color, form or texture that may be specied by the designer. Additionally, the beauty of natural aggregates is greatly accentuated when the aggregates are fused with the color and texture benets of precast. Exposed smooth form nishes without any applied nishes are not recommended. The resulting variations in appearance due to form release agents, air voids, minor irregularities between form treatments and its susceptibility to crazing all will result in a less than favorable nal aesthetic appearance.
Color
It is recommended that color selections be done in the same or similar lighting conditions as the in-place conditions. Interior-use precast should be viewed under incandescent or uorescent lighting. In order to maintain matrix color uniformity, white cement should always be used (as noted in the mix design process) along with color pigments conforming to ASTM C979. Even when the desired matrix color is gray, the use of white cement and gray pigment is still highly recommended. Reliance of color based solely on natural aggregates will carry with it the same variations inherent in nature. When reviewing cost in selections, it is important to consider the source of aggregate if deep exposure is required (local sources are almost always more cost-effective); and to realize that matrix colors such as blue and green are higher cost selections.
Frederick County Public Safety Building
Capitol Finance Building, Richmond, Virginia

Variations in color can be achieved within areas of the building faced or within each individual precast unit. When multiple colors are used, clearly dened breaks in color are required by use of reveals, joints, and prole changes in order to ensure crisp transition. Deep exposure nishes can be achieved either through the use of chemical retardants used to achieve an exposed aggregate nish or through the sand blasting process and related to the degree of which the coarse aggregates are exposed to view. In both these cases, more than just the extreme surface area of the aggregate is exposed, allowing the coarse stone aggregate to project beyond the cement matrix. The exposure should remain at 40% of the narrow diameter of the coarse aggregate in order to prevent the ocurrance of bald spots. Both types of surface treatments highlight the natural beauty of the stone while providing a texture which cannot be obtained by utilizing the lighter nishing techniques. Variations in color can be achieved within areas of the building faced or within each individual precast unit. When multiple colors are used, clearly dened breaks in color are required by use of reveals, joints, and prole changes in order to ensure crisp transition.
Texture
Exposure (or Texture) not only expresses the natural beauty of the material components, but can be used to dene or accentuate specic areas on a building faade. Texture takes advantage of its changing relationship to light to create a range of differences in surface from the subtle to the dramatic. When changing textures or exposures within a single precast unit, clear and well-dened break points are needed similar to those noted above for color. Textured surfaces also have the added benet of hiding the effects of weathering and high-volume use areas since the irregularities in the surface help detract attention from line streaking and diminish trafc use marks. Texture can be achieved through a variety of different techniques, and can range from light exposure to deep exposure as dened below in applied nishes.
Applied Finishes
These are a variety of post-applied techniques used to achieve the desired appearance and character of the faade. The buildings nal appearance is obtained through the combination of mix design selection and the choice of applied nish. Although nal nishes such as brick veneers are cast in natural stone or form liners, they may receive a post-casting nish, they are addressed in a separate section since the critical elements of obtaining the desired appearance are achieved during the pre-pour operation. The depth of the applied nish should take into account the size, function,
articulation and conguration of the units. Final selection of the nish gradation should be made during the mock-up phase and should include recommendations from the manufacturer. Variation of applied nishes within the individual units can be used to enhance the overall appearance of the building. This can be a more cost-effective means of emphasizing and accentuating key components or areas of the facade than the use of multiple mixes. When multiple applied nishes are part of the design, the same logic regarding prole changes and/or reveal work should be applied similar to that of multiple mixes to ensure clean breaks. Acid Etch Finish Acid etching is a process that dissolves the surface cement matrix to expose the sand and, to a lesser percent, the course aggregate. Acid etching is typically used to achieve a light- to- medium-light exposure. The end result is similar to that of natural products such as sandstone or limestone. The etching process leaves a sugarcube appearance which is enhanced by direct sunlight. The decision to incorporate an acid etch nish must be made prior to or during the mix design process since only acid-resistant siliceous aggregates (granite, quartz, etc.) should be used. Carbonate aggregate such as dolomite and limestone, suitable for sandblasting mixes, will dissolve or discolor through the acid-etching process due to their calcium content. Complementary aggregate (ne and coarse) and cement pigments should always be chosen when an acid etch nish is selected. Designers should avoid large expanses of precast without reveal work or prole changes to mask any of the slight variations that may occur through the veining exposure of the natural sand. It is recommended that expanses of unbroken precast be no larger than 4 ft x 6 ft. If an acid etch wash is to be used on deep prole panels, these should be fabricated during the mock-up phase. Acid etching is the crucial second step process when the building faade will include clay products such as thin brick veneers. This process not only helps remove some of the surface latent on the brick during the manufacturing process, but also exposes the sand between the thin brick joints to mimic that of hand-laid brick mortar. It is also used as a safe nish around the brick veneer for incorporated precast features such as lintels, sills, bands, and projections that have all been integrated within the same precast unit. Sand Blasted Finish Sand blast is the generic term used for the abrasive blasting process. Varying gradations of blast material are used to chip away the precast surface. Selection of a particular gradation is dependent upon the desired depth of nish. Sand blasting allows the designer the full range of depths obtainable in precast (light to heavy). On nal exposed surfaces, brush blasting should be avoided because of its inability to uniformly remove all the surface laitance, and because it will leave the same negative effects noted above for smooth form nishes. Light blasting provides a similar appearance to that found in natural limestone without the sugar cube appearance created by acid etching. In contrast to acid etching, blasting tends to be better suited to muting or camouaging minor variations that occur in the manufacturing process.
Example of an acid etch nish
Example of a sand blasted nish

52 THE BUILDING ENVELOPE
This is especially true when addressing deep prole articulations. Deeper blasts have an increased ability to ensure uniformity. However, once blasting exceeds the light level of nish and texture, the end result is more dependent on the natural elements of the mix (aggregates). Complementary aggregates and matrix should always be considered when specifying deeper levels of exposure. A deeper blast can mimic other natural materials such as amed granite, and create interesting plays of light through its texture. Blasting can also be a more economical means of achieving multiple variations within the same unit rather than incorporating multiple mix designs. Blasting creates multiple variations by exposing differing levels of the coarse aggregate in pre-dened areas on each panel. The overall desired effect of texture is also inuenced by the type and selection of coarse aggregate in relation to the psi of the matrix. Softer aggregates will become concave during the blasting process, while harder aggregates will become convex, depending upon the depth of exposure. Since the nal aesthetic of sandblasting is determined mainly through the exposure of aggregates, nal depth decisions should not be made until a minimum of a 4 x 4 mock-up has been reviewed. It is highly recommended that nal depth decisions be made at the precast facility so that depth and gradation changes can be made at the facility to allow the owner or designer to be an active controlling participant in the process. Exposed Aggregate This process is achieved by chemically retarding the matrix, which provides a non-abrasive method of exposing the natural beauty of the coarse aggregates. Unlike the sand blasting process, the chemical retarder does not mute or damage the coarse aggregates. The chemical retarder is applied to the mold surface, which delays the cement paste from setting up. After stripping the panel, the retarded outer surface layer of cement paste is removed with a high-pressure washer. A variety of depths, from shallow to deep, can be achieved depending on the type of retarder used. As with other nishes, variations of exposure within the same unit can be achieved with chemical retarders; however, a clear reveal or prole change is a must for the transition points to prevent bleeding of exposure. The choice of aggregate size is essential when choosing depth to ensure excessive Example of exposed aggregate nish aggregate loss bald spots do not occur. If the owner or designers vision is to enhance the bright, natural colors of the aggregates, then chemical retarders should be used. It is recommended that contrasting matrix and aggregate be avoided to prevent a patchy appearance. Form Liners Form liners offer the designer a wide array of possibilities in terms of shapes, patterns, textures, and designs. The liner material used is dependent upon the desired effect and the number as cast required (from metal, plastic, foam, plaster, wood or elastomeric). Any combination of applied nishes can be utilized in conjunction with form liners. They can be implemented either as the main aesthetic feature or as a highlight, medallion, or logo. Advances in form liner technologies have created a design palette limited only by the imagination. When vast areas of precast will utilize form liners, limitations of liner sizes should be incorporated with reveal work to prevent liner butt joints. Form liners provide the highest degree of texture and will enhance the play of light and shadows, creating a changing appearance of the faade throughout the day. Key placement of night illumination can also complement the effects of the liner.
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A custom form liner was used by The Shockey Precast Group to fabricate these precast medallions for the Philadelphia Criminal Justice Center.
Form liners are a key component when implementing a thin brick veneer. The three main types of brick liners (elastomeric, plastic grids, and snaps) each have their own positive attributes, depending on project design and panel conguration. The selection of a liner should be made with the guidance of the precast manufacturer. When a designer chooses to utilize a form liner, it is important that the designer recognize the lead time required with form liners. Lead time will vary by type of liner or pattern selected. Liners requiring unique artwork will require additional time for the artisan to create the master mold. Form liner lead times can range from between 4 to 8 weeks. When elastomeric liners are used in conjunction with thin brick, a sample run of the actual brick being used is required in order obtain the correct t. The rst 100 bricks from a run are measured and the form liner is based on the average brick size. Not only does the form liner lead time need to be taken into account, the lead time required on the brick must be considered as well. Brick manufacturing will usually fabricate the lighter shades in the beginning of the month and the darker shades at the end (or vice versa). Depending on the time of the month and the type and color of the brick selected, it will normally run approximately four weeks minimum (depending on the backlog of the particular color selected) until the rst run of bricks are delivered.
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DESIGN CONSIDERATIONS
Through this chapter, youll gain a better understanding of the architectural, structural, and MEP design considerations that must be taken into account when specifying total precast systems. Chapter 3 will address topics such as thermal performance, re ratings, oor vibrations, penetration coordination, and load criteria.
Architectural
BUILDING THERMAL PERFOMANCE How is insulation applied?
There are several ways to insulate a precast concrete building. As with other types of construction, methods vary in type and complexity. When a nished wall is required, metal studs can be installed independent of precast panels, allowing for exibility of installation of other features within the walls. Typically, a one-inch air gap is provided between the concrete panel and the metal stud to form a thermal break from the exterior concrete panel. Batt insulation is then installed within the studs to the appropriate thickness required to achieve the desired R-Value or thermal resistance. Gypsum wallboard (GWB) can then be applied to the interior surface of the wall to produce the nished side of the wall. In unnished areas, such as mechanical spaces, stick pins can be applied to the concrete panels with the batt insulation attached directly on the interior of the precast. Although this approach does not provide for the air gap as achieved with the metal studs, it also eliminates the cost of the metal studs, which produce a thermal break at each stud. Insulated sandwich precast panels offer quick installation, since the insulation is installed in the panels during the manufacturing process; however, thermal breaks occur at the edges of the panTHE SHOCKEY PRECAST GROUP , WINCHESTER, VA WWW.SHOCKEYPRECAST.COM DESIGN CONSIDERATIONS 55
els where the solid concrete forms a bridge to the interior of the building. Typically, furring and GWB is still required on the interior of the panel to achieve a nished appearance. The furring also accommodates electrical and telecommunication devices that would otherwise have to be cast into the panels.
How is thermal integrity maintained?

One of the key benets of a concrete structure is its thermal mass. Thermal mass is the ability of a material to absorb heat. When used as an exterior skin, a high-density material like concrete requires a large amount of heat energy to change its temperature. High thermal mass materials act as thermal sponges, absorbing heat during the day in summer and cooling the building by storing heat from the sun over the surface of the building, rather than allowing it to ow into the building. This cycle reverses at night when heat is released back out into the atmosphere. Thermal mass is not a substitute for insulation, since the heat it stores is generally re-radiated to the exterior of the building, but also may be radiated to the interior. The function of the insulation is to form a barrier that stops heat owing into or out of the building. When used in the right combination, these two elements, along with a building design that captures solar light and heat energy, can improve the thermal performance of the buildings and lower the overall energy requirements. A concrete masonry unit (CMU) has less mass than a solid concrete panel. Air bubbles within the units provide insulation value; however, they are less dense and allow moisture into the building. CMU blocks are produced with cores and webs within the blocks, which allow thermal breaks at each web connection. Typically, rigid insulation is applied to the exterior of the CMU to provide the thermal integrity of the wall, eliminating the advantages of the thermal mass principal.
How is the integrity of moisture barrier maintained?

Since concrete is inherently dense, it helps prevent water inltration into a facility, and eliminates the need for additional moisture proong materials required with other veneer systems. CMU is porous, and requires the installation of damp proong or waterproong when it is used. Flashings must also be installed at openings such as windows and doors to compensate for the possibility of water inltration into the facility. Controlling relative humidity can reduce vapor migration. It is typically caused from the afnity for water molecules to be present on the surface of most common concrete building materials. This molecular lm is proportionate to the relative humidity of the space where the panel is located. A major contributor of relative humidity within the space is the HVAC system and its proper operation. If the relative humidity is controlled, the sweating problem is alleviated.
Acoustic Dampening
Sound transmission loss (STC) denes the ability of a barrier to reduce the intensity of airborne sound. Precast concrete walls, oors, and roofs do not usually require additional treatments in order to provide adequate sound insulation. Greater sound insulation can be attained by attaching additional layers of building materials such as gypsum board. Impact insulation class (IIC) is measured in terms of Hertz, and examples of impact
56 DESIGN CONSIDERATIONS THE SHOCKEY PRECAST GROUP , WINCHESTER, VA WWW.SHOCKEYPRECAST.COM
noises can be dened as footsteps and slamming doors. Generally, the thickness or unit weight of concrete does not greatly affect the transmission of impact sounds. IICs can be reduced by utilizing structural concrete oors in combination with resilient materials.
Fire Resistant Design

Precast concrete provides noncombustible construction and performs well in preventing re from spreading within a building. Many times, concrete can be reused after being subjected to a re. Fire resistance of precast concrete is determined by its thickness and aggregate composition. Numerous testing data is available for precast construction and the procedures for determining re resistance are prescribed in ASTM E119. Heat transmission is better controlled by concrete materials, and steel materials will often fail if left unprotected. Concrete construction also does not rely on a sprinkler system which is dependent on an additional water source. Since most of the construction industry has now adopted the International Building Code (IBC), we all abide by the same criteria. Chapter 5 of IBC covers General Building Heights and Areas. Most buildings of a size economical for precast concrete are of Type I construction (see Table 503). The other noncombustible construction, Type II, has small areas. Type IA is mostly unlimited in height and area. Type IB has some limits and slightly lower re resistance requirements (see Table 601). ASTM E 119 Table X3.1 denes two Construction Classications, Restrained and Unrestrained, for spanning members. Restraint for re protection is not equivalent to restraint to a structural engineer. By items III(1) and III(4) of this table, precast concrete is considered restrained. E 119 re test assemblies must meet more than one criterion to pass. Passing criteria are listed below, but not all may be required for every situation: Load support (support of the unfactored loads on the test assembly) Hot gas transmission sufcient to ignite cotton waste Heat transmission an increase of 250o F The average temperature of rebar cannot exceed 1100o F The average temperature of prestressing strand cannot exceed 800o F Hose stream, dened in E 119 for walls, but it is not used for beams or columns. The passage of smoke or other products of combustion through the assembly is not covered by E119.
Construction Precast ComponentRating (hours)
IBC Section 703.3 denes sections 720 and 721 as two methods for determining re resistance rating. 720 is prescriptive, while 721 includes tables. A few simple calculations may be required with 721. Some of the calculated ratings yield the prescriptive result. The IBC prescriptions and calculation results show Shockeys regular construction has the following re ratings:
8 thick and thicker walls 6 slabs 7 thick and thicker slabs 12 Columns and larger Prestressed beams 8 or wider Prestressed beams 12 or wider Double tees with a ange (can include topping) at least 4 thick Double tees with a ange (can include topping) at least 4.6 thick Double tees with a ange (can include topping) at least 5.7 thick
4 3 4 4 2 3
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Table 721.2.3 is comprised of ve charts, which provide requirements for concrete cover to reinforcing for slabs and beams. Other paragraphs cover different precast products. The precast design engineer will ensure compliance with these components. The joints between precast concrete components also have requirements. In general, joints must be protected. For walls, see 721.2.1.3; and for slabs see 721.2.2.4. There are exceptions: 704.7 and 704.8. Note that 721.2.2.4 species that 1 of cast-in-place concrete topping eliminates any re-rated joint ller. The Code does not address connections for re rating beyond ASTM E 119 on restraint. However, most precast concrete sits on a horizontal bearing seat. For instance, beams sit on column corbels. These corbels will have the same rating as the rest of the column, so the beam will remain in place for the same period. Double tees usually sit on beam ledges. These ledges will have the same rating as the rest of the beam so the double tees will remain in place for the same period. Other connections, such as those designed to resist lateral loads, are not considered, as a design re is not postulated to be coincident with either a design earthquake or windstorm. Case Study of an Assembly Not Explicitly in IBC Assemblies that are not explicitly described in IBC can still be accepted by the calculation tools it provides. An example comes from a retail store The Shockey Precast Group built in 2007. The contract drawing detail showed the following:
Elevation through oor.
The double tee ange is 4 thick and the required re rating is 2-hour, which normally requires 4 5/8 of concrete. This assembly meets the criteria through the following: The load support criterion is met from the design calculations and Table 721.2.3(5). Gas hot enough to ignite cotton waste will not pass because the topping is more than 1 thick. Excessive heat transmission does not occur because the two layers of concrete can be added in the same way as two layers of wall per Tables 721.2.1.2(1) and (2) of IBC. This results in a rating of about 3 hours, almost twice the required two hours. The insulation was acceptable because the ame spread index is less than 25 as required by IBC 603.1, Item 2. The temperature of the waterproong system, above 4 of carbonate aggregate concrete, will never be subjected to its ash point by heat transmission through the concrete. These will never be subjected to hot gases because the precast joints are sealed with a reproof caulk.
CODE CONSIDERATIONS -- FLAME SPREAD

The inherent properties of concrete make it a non-combustible material. The ames will not propagate along a concrete panel, but will instead be blocked by the panel. The thermal mass of the panel hinders the spread of heat to the other side by prolonging the time of the heat transfer through the panel, further eliminating the possibility of ames rekindling the other side of the panel.
Precast re and smoke ratings Although precast panels may have the required re and smoke ratings inherent to the product, the joints between the panels require further attention. Section 713 of the IBC states that joints installed in or between re-rated walls shall be protected by an approved re-resistant joint system. Fire-resistant joint systems shall be tested in accordance with the requirements of either ASTM E 1966 or UL 2079. One item to consider when constructing a precast building is the movement of precast oors and roof panels. To accommodate this movement slip joints are required. These slip joints are required to be re rated in order to accommodate oor and roof loads superimposed on any re rated walls. Depending on the rating of the oor or roof structure, a topping slab can be applied to the precast double tees to achieve the required re ratings without providing a separate joint system. If cracks occur at panel joints, these joints must be addressed at that time with a re-rated joint system.
Structural
LOADING CRITERIA Gravity Loads:
Gravity loads generally consist of the building dead loads and live loads. These can act uniformly, as line loads, or as concentrated loads. Typically, the Engineer of Record will provide the live load criteria to the Precast Manufacturer for design of the precast elements. Live loads consist of oor loading based on occupant load, and roof loading based on snow, snow drifts, construction, and code-prescribed minimum roof live loads. The foundation loads can be preliminarily determined from this information. More specic information regarding mechanical and other equipment weights is required as early as possible for design of the precast members subjected to these loads. Additionally, deection criteria must be carefully considered, particularly when supporting curtain wall and partition wall systems.
Lateral Loads:
Generally these loads consist of wind and seismic loading. Criteria for these loads are typically provided by the Engineer of Record. Lateral loads also have an impact on the foundation design, so early coordination with the Precast Manufacturers design is important. Precast concrete can be economically designed to resist high wind events such as hurricanes and tornadoes. The inherent durability and strength of concrete walls provide high resistance to impact and other projectile forces. Precast framing systems also perform well when subjected to earthquake loads. Typical lateral force-resisting elements in total precast structures are shear walls. As an example, on page 31 the stair and elevator boxes in this building all act as shear walls. In some cases, lateral force-resisting elements are integral to the perimeter building envelope, like the Frederick County Public Safety Building pictured on pages 20 and 21.
Other Loads:
The inherent solidity of concrete provides resistance to a host of natural events. Precast concrete can be designed for ood resistance and can easily absorb the effects from wave energy. Precast concrete is highly weather-resistant and performs well in hot and humid climates. Concrete will continue to gain strength in the presence of moisture. Precast concrete is impermeable to wind-driven rain. Precast concrete performs well when subjected to ultraviolet solar radiation.
THE SHOCKEY PRECAST GROUP , WINCHESTER, VA WWW.SHOCKEYPRECAST.COM DESIGN CONSIDERATIONS 59
The environmental characteristics of precast concrete can be modied by the use of pigmentation in the concrete mix.
FOUNDATIONS
Engineer of Record and Precast Manufacturer should coordinate design effort early in the project to determine foundation requirements, particularly if the foundation placement is fast-track. Once a site is selected and general building footprint is determined, a geotechnical investigation should begin as soon as possible. Foundation elevations and depths should be established based on site grades, utilities, frost depths, and other geotechnical considerations. Footings can typically be stepped to avoid utilities, but should not be installed too shallow as to result in conicts with other trades. Foundation embeds should be carefully coordinated between the Engineer and Precast Manufacturer to determine the connections that work best for a particular design. Proper eld location of the foundation embeds is critical to avoid eld modications and project delays. Generally, the precast wall connections are eld-welded to the foundation embeds. Column anchor bolts are preset with the foundation placement and require careful placement.
FLOOR TOPPING SLABS

Field-placed concrete topping slabs are an effective way to deal with camber in the double tees. Principally utilized to provide a level and uniform oor surface, they also perform a key structural function as the lateral force transferring diaphragm. They are generally not utilized at roof levels, unless unusual non-uniform loadings are anticipated. The precast specialty engineer (employed by Shockey) should play the key role in design and detailing of these oor slabs. This should include prescribing the thickness, strength, and other properties of concrete, type, quantity, and layout drawings of reinforcing, construction joint layout (if any), as well as recommended placement methods. Given that much of the precast erection activity has been completed prior to commencement of eld-placement of concrete, the materials are typically supplied and installed by the general contractor or his cast-in-place concrete subcontractor. Quality control is generally provided by the owners independent inspection agency.
FORCE PROTECTION REQUIREMENTS Blast Resistance

The Department of Defense and the Department of State initiated construction methods designed to protect human life from ying debris and building collapse. This section was developed to dene some basic design considerations as they relate to blast resistance for total precast structures. While progressive collapse is an integral design consideration in blast resistance, Blast resistance diagram illustrating standoff distance and charge weight. progressive collapse is not a design consideration that is exclusively considered for blast analysis. Progressive collapse will be covered in a separate section. The Shockey Precast Group is an integral part of the Precast Concrete Institutes Blast /Structural Integrity Committee, and has experience producing projects with blast resistance requirements. Shockey met these requirements using established methods and approaches for determining dynamic loads, structural detailing, and dynamic responses while integrating the following technical manuals:
a. Department of the Army. Structures to Resist the Effects of Accidental Explosions, Army TM 5-1300, Navy NAVFAC P-397, AFR 88-2. Washington, D.C., Departments of the Army, Navy and Air Force. (1990) b. Department of Energy. A Manual for the Prediction of Blast and Fragment Loading on Structures, DOE/TIC 11268. Washington, D.C., Headquarters, U.S. Department of Energy. (1992) c. Department of the Army. Security Engineering, TM 5-853 and Air Force AFMAN 32-1071, Volumes 1, 2, 3 and 4. Washington, D.C. Departments of the Army and Air Force. (1994) d. Department of the Army. Fundamentals of Protective Design for Conventional Weapons, TM 5-855-1. Washington, D.C. Department of the Army. (1986) e. Naval Facilities Engineering Service Center, Guidebook on Protection Against Terrorist Vehicle Bombs. (May 1998) Certain structures have blast requirements to reduce the impact on the structure as a result of detonated explosives typically car bombs and other terrorist attacks. These types of explosions result in dynamic pressures applied to the structure. These explosions typically have much higher pressures and shorter durations than wind or seismic loading. Minimizing impact on the structure due to such attacks can help minimize the impact on the structures ability to be operational, maintain immediate occupancy, ensure life safety and and mitigate the potential for progressive collapse. The two main components of calculating blast pressure are the charge weight (pounds of TNT or alternative explosive) and the standoff distance (distance between structure and detonated explosive). Minimizing dynamic pressures on structure due to blast can be achieved by increasing the standoff distance through the use of perimeter security -- bollards, fencing, landscaped berms, or anti-ram walls and/or decreasing charge weight. The exterior skin (precast & glazing) should be designed to prevent the blast wave from entering the building. Ideally, the exterior skin will behave elastically and absorb energy transferring loading into the structural diaphragm. Cladding a total precast structure with architectural precast concrete or building redundancies within the structural members can assist in blast resistance design. Additionally, spanning exterior skin oor-to-oor will allow loading to transfer through the structural diaphragm. Exposed structural columns or transferring dynamic loading using connections from the exterior skin directly into the columns should be avoided wherever possible. The structural diaphragm to resist blast loading can be comprised of interior shear walls, moment frame spliced columns, or a hybridization of the two. The glazing manufacturer will also have to consider blast resistance for such projects. Whenever possible, the building should be oriented to minimize faade exposure to blast. Example: Here is the same C-shaped structure oriented in two separate fashions. Option (2) provides less faade exposure. It is critical that the precaster, window manufacturer, and blast engineer be involved in early design and development activities since determining the materials utilized for faade plays a large role in the performance of the structure. Identifying relative capacities of faade elements in conjunction with building performance level / blast criteria helps to determine structural support elements. Progressive Collapse Designing for progressive collapse can be dened as the evaluation of a local failure from an element distributed into other elements resulting in the collapse of a structure or a signicant part of the structure. The United Facilities Criteria (UFC) has published Design of Buildings to Resist Progressive Collapse, which can be found at: http://www.wbdg.org/ccb/DOD/UFC/ ufc_4_023_03.pdf.
DESIGN CONSIDERATIONS 61
Blast resistance diagrams Option 1 and Option 2
Richmond Convention Center
EMBED CONSIDERATIONS
The coordination of embed locations between the Precast Manufacturer and the Engineer of Record is very important to ensure a smooth and uninterrupted project completion. The Engineer of Record typically provides the design reactions and embed plate footprint for the Precast Manufacturer. Items requiring embeds include canopy structures, elevator rail mounts, stairwell railing mounts, piping and equipment mounts, as well as any other items tied into the precast structure. Aesthetics must also be considered so that embeds can be hidden or made inconspicuous.
Connection embed, Frederick County Public Safety Building
Handrail embed in stairs.
Handrail embed in stairs.

62 DESIGN CONSIDERATIONS
Unistrut
SPECIAL CONDITIONS Raised Floors:

Access raised oors are used frequently to facilitate HVAC servicing and communications, and electrical runs below ofce areas and computer rooms. Precast oor systems can easily be adapted to raised oor systems and can be designed for this additional oor load. Variances between oor levels can be accomplished with additional oor topping or other special detailing. Following is an example of a typical raised oor.
Microwave towers/antennae:
Concentrated loads from this type of equipment can vary substantially. Input from the manufacturer early in a project can be valuable information to incorporate into the precast design. Tower frames and antenna racks should more effectively be placed over column or tee stem locations to avoid issues with slab punching shear.
Vibrations:
Floor vibrations can cause perceptibility problems with building occupants and should be considered on all projects, particularly those with longer spans. Vibrations are particularly prevalent in parking garages. Precast oor construction is inherently stiffer than some other types of construction and can be designed to mitigate vibration characteristics. A building can be perfectly sound structurally, but if the oors vibrate excessively when groups of people walk by, those sitting still could notice the vibration and become uncomfortable. In order to make the occupants feel at ease in the building, the oor must be designed to be stiff enough to not ex objectionably when a moving load passes. How stiff is stiff enough? The Precast Concrete Institute (PCI) has established guidelines regarding the amount of stiffness necessary to negate the possibility of objectionable vibrations. Calculations are performed based upon the size and length of the oor member, along with its loading. Based on this calculation, a minimum natural frequency required for vibration prevention is calculated. A oor member is then designed that has a natural frequency higher than the calculated minimum. In addition to selecting a double tee with a natural frequency greater than the calculated minimum, it is also recommended that the vibration frequency be kept above 3 Hz if possible. Since humans have difculty detecting vibrations higher than 3 Hz, any vibrations above that frequency become essentially imperceptible.
THE SHOCKEY PRECAST GROUP , WINCHESTER, VA WWW.SHOCKEYPRECAST.COM DESIGN CONSIDERATIONS 63
The ideal strategy is to avoid objectionable vibrations. If vibrations are unavoidable, then the goal is to make all vibrations imperceptible. The Shockey Precast Group routinely spans 50 feet with our double tees in ofce buildings and stores. We not only exceed the minimum values required, but also exceed the 3 Hz recommendation as well.
Operable Partitions:
Operable or hanging partitions present unique structural challenges, but with early coordination, these challenges can be easily considered during the design process. It is important to receive input from the partition manufacturer as early as possible to obtain partition loads and preferred structural support systems. Specic deection criteria should also be obtained early, to facilitate the design of precast in the areas where operable partitions will be used.
Interior partition details.
MEP equipment/piping:
Large hanging or equipment loads should be provided to the precast manufacturer as early as possible for incorporation into the design. When carefully coordinated, embeds may be provided to support special framing for this equipment
Heavy Ofce Equipment:

High density ling or storage systems, computer server rooms containing multiple fully loaded equipment rack and other areas containing special equipment can place tremendous loads on the structural system. Typically, structural load requirements for these types of ofce equipment may range between 100 to 300 psf (pounds per square foot). Equipment locations and areas of potential heavy load concentration, such as the carriage wheel rails beneath high density ling systems, must be identied as early as possible in the design phase. Coordination with the structural precast fabricator is imperative in order to accommodate these loads in the precast member design.
Large Openings:
The exibility of precast allows for the accommodation of large openings. Embedded concrete connections can be used to facilitate attachment of windows and curtain walls. Unlike steel construction, large window wall openings typically do not require supplemental steel framing above and below the window to provide support. Substantial savings can be gained by the elimination of miscellaneous steel framing; however, careful detailing with the intePunched windows detail. rior nishes is recommended to assure a proper appearance within the space.
Expansion Joints/Building Movement:

Concrete does not expand and contract thermally as much as steel, but jointing between concrete materials and other building materials must be carefully detailed during design. Particular care should be considered at junctions between structural and non-structural elements and also between dissimilar materials such as concrete and masonry or steel. Thermal, structural, and moisture related movements can all cause cracking and should be addressed early by the manufacturer and designer. Typically, metal studs and gypsum wall board are used to frame the interior spaces so these can be separated from the precast panels to keep each system independent. This allows the window system to be detailed with a exible joint material to allow the material to move independently.
Access to Connections:
Sequencing of erection of precast members should carefully consider access to connections. When concrete panels are tied-back to steel construction, eld issues can arise if the General Contractor cannot perform the connection work.
Stairs:
Modular precast stairs serve to simplify the stair erection process on building projects. The overall project schedule can be expedited through the inclusion of modular precast stairs because there is then no need for a separate stair framing subcontractor or concrete lled pans. Stair attachments can easily be made in the eld and hidden from view from the public. Special care should be considered when stairs are on the exterior walls to account for the thickness of any interior wall insulation. Connection details should be concealed or lled to allow the precast panels to serve as the nish wall inside these spaces.
Access to connections detail.
Roof Drains:
One thing to consider when designing any structure is how the roof will drain. This can be accomplished in a number of ways. The use of internal roof drains is a common practice; however, this can lead to roof leaks or pipe leaks within the space. A better solution is to slope the structure to the rear of the building and allow sheet ow to scuppers that can direct the rain water to downspouts strategically placed on the exterior face of the building. However, when using this technique, one must always be aware of clear height requirements within the building, since the entire slope of the roof is towards one direction, making a deeper cut in the rear of the building. Careful coordination is required with the exterior panels to assure that the scuppers line up with the top of the roof and overow scuppers are placed correctly. Another consideration is the clearance requirements for the downspouts below grade and above the footings.
Rooftop screenwall
Top to bottom: HVAC, conduits, window coordination, and stairs.
Post-Completion Modications
There is exibility in the removal of portions of the double-tee anges to facilitate MEP penetrations to enable intercommunicating stairs or other changing building uses.
MEP
COORDINATION OF PENETRATIONS
During design of the mechanical system, careful consideration must be given to the placement of mechanical equipment and the location of ductwork and piping penetrations. Placement of large equipment on the roof should also be given special consideration during the design process. Placement of packaged rooftop air handling units is probably the most critical item to consider during the design of the facility. Centrally locating the air handling units in the middle of the area to be served allows for the shortest and most economical HVAC ductwork runs. Placement of the packaged air handling units should be closely coordinated with the precast system utilized for the roof construction. The location and size of supply and return air openings vary between manufacturers. Some are in close proximity to one another, while others have a greater distance between them. Some are parallel, while others are at right angles to each other. The size of the required supply or return duct opening may limit the capacity of the rooftop unit, if the duct size can not be accommodated in the roof slab.
Example of penetration in double tee. Physical sizes and weights of units vary with the conditioning tonnage of the unit. Unit weights vary from around 1,000lbs to over 17,000lbs for the largest air handling units. A properly designed precast roong system can easily carry this load while also allowing for the proper sized holes to allow the ductwork to pass through. ASHRAE 90.1 and International Energy Code. The Shockey Precast Group meets the requirements in 90 % of the United States with precast wall panels with 2 insulation having a minimum R-value of 9.5 hft2F/Btu.
66 DESIGN CONSIDERATIONS
Design for Economy

There are several areas that have the potential to signicantly increase precast production and erection costs. By being aware of these areas, and by considering the guidelines outlined below, the architect and owner can design a building that is both striking and economical.
COMPONENT SIZE AND GEOMETRY

When designing for economy, the designer should be aware of component size and geometry. It is generally more economical to use a lesser number of large pieces than a greater number of smaller pieces. A lesser number of large pieces equals less total set-up time to produce the material, fewer trips required to ship the material to the job site, and fewer operations to erect the material. All of these save time, labor, and money. In addition to size, the geometry of the pieces can play a large role in cost savings. Pieces that are shaped to serve multiple functions can reduce the overall piece count, which saves money. An example would be a shear wall that has a corbel built into the wall to carry a beam (as opposed to a column standing beside the wall and the column supports the beam). By using the wall with a corbel, the column can be eliminated, which then eliminates the work of designing, producing, shipping, and erecting the column. The result is a substantial savings.
DUAL-USE COMPONENTS AND ARCHITECTURAL FEATURES

Dual-use components as they relate to total precast structures can be dened as structural components that have architectural features. Architectural features are created using a variety of shapes, colors, textures, and applied nishes. When selecting accent reveals or rustication lines, it is important to tie them in to the chosen joint size. Triangular reveals are to be avoided where possible because they are difcult to afx to the forms. Instead, a trapezoidal reveal will provide a at nailing surface to the form builders and help minimize possible nail-hole irregularities. Be sure to include reveals between any and all color breaks - when two separate architectural mixes are utilized within the same panel, it is strongly recommended that designers include a reveal between the two mixes to provide the casting crew a distinct stopping point and to help reduce color bleed. This will help ensure an unwavering and smooth break line as illustrated in the gure below. When choosing reveal sizes also consider limiting depth to 3/4. Deep reveals decrease the effective section of the panel, thereby reducing panel strength and increasing the chance for panel cracking. Additionally, in dual-use components, deep reveals may hinder the optimal reinforcing and or strand conguration.
Color #1 Caulk with backer rod Trapezoidal Reveal
Color #2
Panel Joint
Reveal
Facial projections can add a unique accent to your building project. Because these features are cast with panels bottom-in-form (exposed architectural nished face towards the ground), a minimum draft dimension is necessary in order to strip panels out of the form. Without proper draft, suction forces generated between the concrete and the form may cause the pieces to bind up during stripping and possibly damage the piece and or the forms. To ensure this does not occur, Shockey recommends a minimum draft of 1:6 on facial projections as noted on the sketch below. It should also be kept in mind that facial projections tend to increase production costs, since forms need to be built-up to accommodate the features.
Loops for stripping
Facial projection
Forms built up to create facial projections Minimum draft
Panel in nal erected position
Panel as cast
MODULARITY
When designing for economy, it is important for the designer to understand that signicant changes to proles and other architectural features such as reveals will adversely affect the project schedule in terms of design, drawing, and forming changes. In addition to minimizing variations in prole changes or architectural features, the designer should also consider minimizing changes in panel heights and widths as too much variation in panel sizes will increase total piece-count and add substantially to production and shipping costs, as well as add time to the overall production schedule. Finally, the designer should attempt to match interior component sizes with exterior component sizes. For example, if using 12 double tees, dont design for 30 exterior bays. Maintaining consistency and a relative degree of simplicity will result in a structure that is truly designed for economy.
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COMPONENTS AND CONNECTIONS

In this chapter we will examine typical precast components utilized in total precast systems, and gain a better understanding of the unique connection considerations that must be taken into account when building with precast. This section will highlight the various components and connections used in construction of the Frederick County Public Safety Building, as well as their interaction with other building materials. Ideally, this chapter will give you a clearer picture of the relationship between precast components and the surrounding construction elements.
Insulated Wall Panel to Double Tee

Connection of a double tee with cast in place topping to an insulated wall panel. Connection types, and styles of embeds vary as conditions require. This is detail is usually at the roof condition.
COMPONENTS & CONNECTIONS
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Insulated Wall Panel to L-Beam Connection of a double tee to an inverted tee-beam to an insulated wall panel. Connection types, and styles of embeds vary as conditions require. This detail illustrates conditions at the roof condition. Similar condition can occur at the oor. This condition could allow for building additionexpansion by removing and or possibly relocating the wall panel at a future date.
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Roll Restraint Corbel Variation of a roll restraint corbel these types of connections are hidden from view because they normally occur above the nished ceiling line where AC/MECH/PLUMB occur.
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Rectangular Beam to Column Dap of rectangular beam permits reduced oor to oor height requirements.
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Double Tee to Wall Top detail illustrates how an exterior cornice feature (as a separate precast piece) is attached to the exterior load bearing wall panel. Bottom detail shows a typical connection between the double tee and the wall panel.
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Double Tee Flange to Flat Slab w/2 Offset This detail illustrates the exibility needed when the oor system must depress in portions of a double tee oor area in order to accommodate depress systems.
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Wall to Column This plan view at the corner of a structure shows how a column accommodates the assembly of load bearing beam, double tee oor, L-beam members, and insulated wall panel units.
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Column to Inverted Tee Beam An example of a connection of an inverted tee beam to column.
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Double Tee Flange to Wall Panel Typical Double tee connection to wall panel.
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Double Tee Flange to Double Tee Flange Typical double tee to double tee connection at the anges.
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Double Tee to Beam Typical connection of dapped double tee to inverted tee beam condition. Detail illustrates embed material needed, however, embed material requirements vary depending upon conditions. Placing daps in the double tee stems as shown reduces the oor to oor height. Eliminating the dap at the stem when possible lowers costs and simplies construction. See similar details without daps.
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Double Tee to Inverted Tee Beam Typical connection of double tee to inverted tee beam condition. Detail illustrates embed material needed, however, embed material requirements vary depending upon conditions. Placing daps in the double tee stems as shown other details reduces the oor to oor height. Eliminating the dap at the stem when possible lowers costs and simplies construction. See similar details illustrating daps.
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Spandrel to Column This plan view at the column shows how a column accommodates the assembly of load bearing spandrel beam and double tee oor members. Connections of the spandrel to column are made by sleeves through the column.
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Beam to Column An example of a connection of an inverted tee beam to column.
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Wall Panel to Wall Panel
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Column to Spandrel This 3D view at the column shows how a column accommodates the assembly of load bearing spandrel beam members. Connections of the spandrel to column are made by sleeves through the column.
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Column to Inverted Tee Beam Connection of inverted tee-beam to column and an insulated wall panel. Connection types, and styles of embeds vary as conditions require. This condition could allow for building additionexpansion by removing and or possibly relocating the wall panel at a future date.
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Double Tee to Inverted Tee Beam Typical connection of double tee to inverted tee beam condition. Detail illustrates embed material needed, however, embed material requirements vary depending upon conditions.
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Double Tee to Double Tee This detail illustrates the exibility needed when the oor system must depress in portions of a double tee oor area in order to accommodate depress systems.
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Double Tee to Column
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Coordination with other Trades

WINDOWS Curtain Wall Systems
Curtain wall glazing systems should be free standing [Gravity (vertical) loads to foundation with wind loads (horizontal) transferred to structural precast] up to a maximum height of 30 feet. Curtain wall glazing systems are typically constructed in multiple level sections with each of the sections requiring transfer of both wind and gravity loads to the precast at the break points. Precast structure must be designed to handle the loads transferred from the curtain wall glazing system.
Curtain wall detail.
Typical wind loads are not normally a problem. Gravity loads can normally be handled by the precast, but deections of the precast under load may exceed the curtain wall glazing system connection tolerances and adjustability. Where possible, stout precast members (beams) should be integrated into the building design to handle loads developed by the curtain wall glazing system. Cambered, thin-sectioned precast members (edge of double tee ange) will not normally be able to be economically designed to handle the loads imparted by curtain wall glazing systems. Allowable beam deection needs to be part of the early coordination requirement. Coordination of locations for embedments, along with magnitude and direction of forces being transferred into the precast, must be made early in the design development so the precast engineer can adequately design the precast members to handle the requirements.
Punched Window Conditions

Panelization or jointing of precast to accommodate punched windows is important. Punched window openings should be accommodated in a single precast unit or the end of a window opening should be aligned with a joint in an adjacent precast panel. When a window opening is detailed within a single precast unit, the window can be installed prior to shipment on the jobsite. This will help minimize eld installation costs and schedule for the window manufacturer; however, it is important to remember that shipping limitations may dictate the size of panels. Several types of window systems work well for punched windows, including stick built systems, unitized framing (framing prefabricated in shop glazing assembled on site), and unitized framing systems (fully glazed frame assembled on site or in panel prior to shipment).
COMPONENTS & CONNECTIONS 89
Curtain wall.
Ribbon Windows
Panelization/jointing of precast to accommodate ribbon windows is more important than simple punched window units. The space formed for the ribbon window units is normally created by the exposed edges of multiple independent precast units. Erection and production tolerances require greater exibility of the ribbon window framing members. Segmented window framing can help allow for window tolerances to conform with camber in panel. Types of window systems that work well for punched windows include: Example of ribbon window, Stoneleigh at Westelds ofce stick built systems, unitized frambuilding ing (framing prefabricated in shop glazing assembled on site requires additional tolerances in caulk joints), and unitized framing systems (fully glazed frame assembled on site requires additional tolerances in caulk joints).
Examples of ribbon window detail.
Tolerances
Caulking tolerances require a minimum of 3/8 for warranty purposes. Ribbon window units may require at least a 1 tolerance on all sides of the rough opening size of the window units to accommodate precast tolerances. This is contingent upon anticipated camber in precast and live loads on the precast. Punched window units contained completely within a single precast piece requires a tolerance on all sides of the rough opening size of the window unit to accommodate precast tolerances.
MEP
DRAWING COORDINATION -- BUILDING INFORMATION MODELING (BIM) What is BIM?
Building Information Modeling (BIM) brings together the design-construction process through collaboration and interoperability. A BIM serves as a 3-dimensional computer model as a single repository for drawing and database information. When needed, the required drawings, such as elevations, details, plans, as well as non graphical format, can be extracted to a 2-D graphical representation. BIM has levels of entry where one can integrate portions of the building team. BIM can be used to collaborate and integrate with areas concerning architects, engineers, precast manufacturers, and other consultants to create a comprehensive 3-D model of the project. Further opportunities exist with delivery sequencing, site access and trafc, fabrication schedule and coordination with delivery into the coordination process. Leaders of rms adopting BIM have seen a need to change attitudes because BIM requires a project-by-project approach. BIM is a business-changing software that requires collaboration throughout the building process where new management techniques are necessary to fully utilize its potential. BIM within the ofce requires more than a software change or new technology.
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3D model of Frederick County Public Safety Building created using Tekla Structures software
Users must adopt a behavioral approach to the change, not one of a technical view. The precast Building Information Model can be viewed in the following manner: A complete 3-D digital representation of a building system or subsystem, including exact locations and sizes of objects. Precast building systems represented by their own BIM and created by precast designers and their consultants. The BIM model integrated with other BIM models. BIM information is extracted to enable collaboration with team members. Precast BIM models are specically used to facilitate the coordination, manufacture, and delivery of system components to the erection site. Collaboration of BIM in order to extract information for visual or documented media by use of its collaboration teams is a typical feature of BIM.
POINTS THAT NEED TO BE CONSIDERED WHEN WORKING WITH BIM: Set up team information ow, collaboration integration. Assign a BIM team leader. Determine what will be modeled and the extent of detailed information that should be incorporated into the model. Establish that the model will always be updated and maintained. Decide on project rules and best practices. Determine who will have ownership of the model. Dene and establish if a neutral common model will be used. Determine degree of software compatibility between BIM models. Conrm hardware effectiveness.
Effective Use of BIM
Creation of a 3-D model in a BIM-oriented fashion requires forward thinking concerning planning and information sharing within the project team. The early integration between the design team, architect, and precast engineering team is highly desirable. With the use of BIM, decisions and information ow begin earlier and progress at an uncommonly fast pace, making team collaboration and leadership essential.
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THE SHOCKEY PRECAST GROUP AND THE BUILDING INFORMATION MODEL

For The Shockey Precast Group, interest in the BIM world began to intensify in mid 2001 with the formation of the PCSC (Precast Concrete Software Consortium). The organization was created to introduce 3D modeling software designed specically for the precast industry of North America. The PCSC, as the voice of the North American precast industry, played a unique role in guiding the software development cycle. The consortium chose Tekla to jointly develop a nal specication of a precast modeling platform. Over the next few years, The Shockey Precast Group was actively involved with the PCSC in the development of TEKLA STRUCTURES, the industrys rst 3-D BIM modeling software. Shockey began precast-specic 3D modeling during the PCSC software developmental trials. Over a four-year time span, Shockey advanced from modeling pilot projects to ghosting projects to actual commercial applications. The full platform was released in September 2005. David Orndorff, Vice President Engineering for The Shockey Precast Group, played a key role as Technical Committee Chair for the PCSC. Tekla Structures is the rst real parametric 3D- modeling software for the concrete industry. The integrated application contains all of the reinforcements and information required to create and manage complete 3D building models, regardless of material or structural complexity. The same model can be utilized for producing analysis and design results, drawings and reports. When changes do occur, the built-in intelligence automatically stores the modied information. Tekla Structures minimizes overlapping work phases and errors, which translates to shorter project lead times, signicant cost savings, and improved building quality. The Tekla Structures solution covers the entire structural design process from conceptual design to detailing, fabrication and construction site control, providing an even more competitive future for the entire structural design industry.
Tekla Structures, IFC, API

The data exchange can be accomplished using multiple data formats, including the open-format Industry Foundation Classes (IFC) standard that enables communication between different software and disciplines in the building industry and Open API (Application Programming Interface) to enable a wide range of third-party applications to integrate their functionality and/ or communicate with the 3D modeling environment. Applications such as MS Access, Excel, Word, or Mathcad, as well as commercial MIS and ERP software, can receive data from the TEKLA STRUCTURES model, run calculations, and then return results back into the model. The Open API also makes it possible for users and 3rd party vendors to develop plug-in applications and additional functionality on the Tekla Structures platform. Tekla has acknowledged the importance of data exchange, and has worked within the International Alliance for Operability (IAI) to develop IFC. The latest milestone in the support for open data exchange mechanisms in building information modeling is the IFC 2x3 certication. Tekla Structures has received the IFC 2x3 1st Step Certication as part of the buildingSMART initiative of the IAI.
Engineering at the Forefront of the Industry

SPGs Engineering staff consists of 28 professionals (six of whom are registered engineers), para-professionals, and support staff. Our engineers have a combined total of over 120 years of structural design & analysis experience, and our drafting modelers have a combined total of over 250 years experience. The Shockey Precast Group has played a key role as Technical Committee Chair for the Precast Concrete Software Consortiums Phase II initiative with the Tekla Corporation to develop a nal specication for a new precast-specic 3D solid modeling platform.
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The PCSC, with an effort begun in 2001, and lasting through 2005, guided Tekla in its development of the actual software. SPGs Engineering Information Manager, as PCSC Technical representative and Software Evaluator, utilized his years of precast experience to give voice to the North American precast industry, and highlight its specic needs. The Tekla software is a signicant innovation for the precast industry, as it will enable full integration of engineering, production, and construction operations through advanced information technologies. With an effort begun in 2001, and lasting through 2005, the PCSC and Tekla partnered to develop this signicant innovation for the industry. Full-scale implementation of Tekla Structures began at SPG in the Fall of 2005. Today, SPGs Engineering department utilizes this and other advancing technologies to stay on the cutting edge of the industry. Numerous presentations and case studies have been delivered at 3-D modeling, BIM conventions throughout North America.
Frequently Asked Questions about BIM

Drawing Coordination/BIM Coordination Q: The more intense coordination in the design phase, the less time required in the eld? SPG: Thats correct.
Q:
SPG:
Tekla:
Does The Shockey Precast Group/TEKLA have the capability to provide scaled drawings for discipline coordination? Result should be scaled drawings for each discipline to verify openings, dimensions, and architectural details. Yes. Tekla has a robust capability to generate scaled drawings from the model, or any part of it. However, we anticipate that much of the architectural and MEP coordination will take place directly within the model itself. This can be done both within the Tekla environment or a third party application via the usage of shared 3D neutral les (see below).
Q:
SPG:
Does TEKLA have the capability to act as building software to coordinate conicts with the precast such as ducts running into walls or tting into the space between the double tees or below the double tees but above the ceiling? Also, lights tting with sprinkler piping, HVAC ductwork, and domestic and hydronic piping. Yes, see above.
Q:
SPG: Tekla:
With which software is TEKLA compatible? Autodesk ABS 2006 (Automated Building Systems) for Mechanical, Electrical, Plumbing; ADT 2006 Architectural Desktop; Autodesk REVIT Architectural and Systems; or other BIM (Building Information Modeling) programs. Yes, Tekla is compatible with all other IFC compliant BIM software. It should be noted that this compatibility is bi-directional, meaning we can both write and read these le types out and in. In addition to IFC, common 3D neutral le types also include 3d Dwg, dgn, and dxf for the purpose of clash/collision-detection. For the Autodesk-based applications listed above, IFC or dwg will be the preferred mode of interoperability. For all other BIM applications, IFC will be the most supported.
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Q: SPG: Q: SPG: Tekla:
Can our items show up on the same screen/drawings as TEKLA/precast items? Yes. Can TEKLA be shared with disciplines? Can it be installed on a design rms computers for use with the design rms BIM programs? Yes. Please see IFC comments above.
Q: Tekla:
How well are architectural features seen onscreen with TEKLA? Geometries created within Tekla are optimized for construction/fabrication purposes. Geometries created within Architectural packages are fully supported via the same above methods of interoperability (this would include smooth curves). Architecturally purposed visualization, such as photo-rendering, ray-tracing (i.e. showing reectivity), and texture mapping, is not yet supported in the Tekla environment. What was the hardest thing about changing the way of working... and why was the change worth it? Old-style 2D mindset in new 3D world. Were all used to providing as much information as possible in the erection drawings in order to provide current and accurate information for the production drawing crew. Now that production drawings are related to the model, that need has been greatly minimized because dimensional information already exists within the model. If its in the model it will be in the production drawings. What do you feel is the most dramatic effect of 3D modeling? Were accustomed to providing as much information as possible in erection drawings. Now that production drawings are related to the model, dimensional information already exists within the model. All drawings are automatically updated and generated as modications are made. Our detailers see immediate visual recognition of spatial conicts.
Q: SPG:
Q: SPG:
Q: SPG:
What do you feel are the most powerful features of 3D modeling? The collaborative features are enormously benecial. The model is the common data source for anyone who accesses it from the initial modeler, to downstream engineers, to viewers in manufacturing operations. This element has great potential. Shockey employs a number of structural engineers, technicians and contracts 15 technical consulting rms that perform roughly 60% of our engineering and drafting. We require all of those consultants to be on a Tekla Structures platform. Our information management system is built around Tekla Structures. We create information only once end of story.
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LEED CONSIDERATIONS LEED Criteria

Potential LEED Points for Buildings Utilizing Precast Concrete, Based on LEED-NC Version 2.2
SUSTAINABLE SITES Credit 5.1 Protect or Restore Habitat

(1 Point) Requirements: On greeneld sites, limit all site disturbance to 40 feet beyond the building perimeter; 10 feet beyond surface walkways, patios, surface parking and utilities less than 12 inches in diameter; 15 feet beyond roadway curbs and main utility branch trenches; and 25 feet beyond constructed areas with permeable surfaces that require additional staging areas in order to limit compaction in the constructed area. OR Restore or protect a minimum of 50% of the site area (excluding the building footprint) with native or adapted vegetation. One of the strategies recommended by LEED for achieving this credit is to utilize tuck-under parking, such as precast concrete parking structures, to limit site disturbance. Another way in which the use of precast panels can contribute to achieving this credit is by providing minimal disturbance to the site during the erection of panels. The panels require no more than a few inches of clearance, whereas other methods such as cast-in-place tilt-up panels require signicantly more.
Below: Example of erecting within footprint of structure.
LEED CONSIDERATIONS
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Credit 5.2 Maximize Open Space

(1 Point) Requirements: Limit the size of the development footprint to exceed the local zonings open space requirement for the site by 25%. Again, one of the strategies recommended by LEED for achieving this credit is to utilize tuckunder parking, such as precast concrete parking structures, to maximize open space.
Credit 7.1 Heat Island Effect (Non-Roof)

(1 Point) Requirements: Place a minimum of 50% of parking spaces under under cover. Any roof used to shade or cover parking must have an SRI (Solar Reectance Index) of at least 29. Materials with a higher albedo (reectivity) will reduce heat absorption and the heat island effect. To avoid having to treat concrete with a light-colored stain to raise the albedo rating, supplementary materials, such as ground, granulated blast furnace slag can replace a portion of the cement in the mix. This material is lighter in color and more reective than Portland cement (it is also a recycled material, See Materials and Resources Credit 4) and increases strength and durability. Another option is to use white cement. Typical weathered concrete has an SRI of only 19, whereas weathered white concrete has an SRI of 45 (86 for new white concrete).
Credit 7.2 Heat Island Effect (Roof)

(1 Point) Requirements: Use roong materials having an SRI equal to or greater than 78 for a low-sloped roof, or 29 for a steep-sloped roof for a minimum of 75% of the roof surface. Strategies recommended by LEED for achieving this credit include the installation of a highalbedo roof. For most buildings utilizing precast concrete, the concrete surface on the roof will not be directly exposed; however in cases where a parking structure comprises the upper oor(s) of a structure, a higher albedo surface (such as the precast concrete options described in Credit 7.1) will contribute to the reduction of the heat island effect. In addition to reducing the heat island effect, the increased reectivity can reduce the amount of heat absorbed by the building envelope, which will decrease the load on building HVAC systems (See Energy and Atmosphere Credit 1).
ENERGY & ATMOSPHERE Credit 1 - Optimize Energy Performance

(1-10 Points) Requirements: Achieve increasing levels of energy performance (from 10.5% to 42%) above the baseline in ASHRAE Standard 90.12004. The use of insulated sandwich wall panels can contribute signicantly to a reduction in energy usage. By reducing building envelope heat gains/losses, the cooling and heating loads on the building HVAC systems will also be decreased. The dense material (thermal mass) helps to absorb heat during the day and moderate daily temperature swings. This helps to shift peak loads from mid-afternoon in the summer to after 5 p.m. when most loads related to occupancy are reduced. Large precast panels also have minimal joints, which will reduce the amount of uncontrolled inltration, again decreasing the load on building HVAC systems.
MATERIALS & RESOURCES Credits 1.1 and 1.2 Building Reuse*

(1-2 Points) Requirements: Maintain 75% / 95% of existing building structure and envelope.
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LEED CONSIDERATIONS
These credits should be obtainable when renovating buildings with a precast concrete shell. The main factor in building reuse is the durability of the original structure. Precast concrete panels have a long service life due to their durable and low-maintenance concrete surfaces. A precast concrete shell can be left in place when the building interior is renovated.
Credits 2.1 and 2.2 - Construction Waste Management

(1-2 Points) Requirements: Divert 50% / 75% construction waste from landll. While precast contributes signicantly toward reducing the amount of waste material that is sent to landlls by providing no on-site waste (since only the needed precast components are delivered, and there is no debris from formwork and associated fasteners), this credit is most often applied when the precast material from an existing structure is recycled. It is frequently crushed and reused as aggregate for road bases or construction ll.
Credits 4.1 and 4.2 Recycled Content

(1-2 Points) Requirements: Materials with recycled content (Post-consumer + pre-consumer) constitute 10% / 20% of total value of project material. Supplementary materials can replace a portion of the cement in the mix, and those materials are considered post-industrial (pre-consumer) recycled ingredients. Fly ash, the residue remaining from fossil-fuel power plants, can replace some of the cement in precast concrete. Often, the use of y ash and other supplementary materials in a mix can produce a more durable product than a total-cement mix can provide. Recycled concrete can be used for 5-20% of aggregate in a mix. According to the Concrete Reinforcing Steel Institute, the reinforcing steel used in precast has over 90% recycled content.
Credits 5.1 and 5.2 - Regional Materials

(1-2 Points) Requirements: Materials that are extracted, processed and manufactured regionally (within 500 miles) constitute 10% / 20% of total building materials based on cost. In virtually all cases, building site locations have a precast plant located well within the required 500 mile radius (usually less than 200 miles). The raw materials used to produce the precast concrete components cement, aggregate and rebar usually come from sources that are also within 200 miles of the precast plant.
IEQ (INDOOR ENVIRONMENTAL QUALITY) Credit 3.1- Construction IAQ (Indoor air Quality) Management Plan
(1 Point) Requirements: Develop and implement an IAQ Management Plan for the construction and pre-occupancy phases of the building, to include meeting or exceeding the recommended Control Measures of the Sheet Metal and Air Conditioning Contractors National Association (SMACNA) IAQ Guidelines for Occupied Buildings under Construction, 1995, Chapter 3. Using precast concrete can help meet these requirements because it is delivered to the site in pieces that do not require fabrication, processing, or cutting. This reduces the amount of dust and airborne contaminants on the construction site.
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Credit 4.1- Low Emitting Materials (Adhesives & Sealants)

(1 Point) Requirements: All adhesives and sealants used on the interior of the building shall comply with the VOC (Volatile Organic Compounds) limits established in South Coast Air Quality Management District (SCAQMD) Rule #168. See Credit 4.2 below.
Credit 4.2 Low-Emitting Materials (Paints & Coatings)

(1 Point) Requirements: Architectural paints, coatings and primers applied to interior walls and ceilings shall not exceed VOC content limits established in Green Seal Standard, GS-11, Paints, First Edition, May 20, 1993. Low-VOC materials can be used for not only form-release agents, but also for curing compounds, dampproong materials, wall and oor coatings and primers, membranes, sealers and water repellent. Another IAQ benet is that precast concrete is not damaged by moisture and provides no nutrients for mold growth. Precast also offers no off-gassing that can cause deteriorated air quality.
INNOVATION & DESIGN PROCESS Credits 1.1-1.4 Exceptional Performance or Innovative Design
(1-4 Points) Requirements: Demonstrate that exceptional performance has been achieved above the requirements set by LEED-NC and/or innovative performance in Green Building categories not specically addressed by LEED-NC. Past precast projects have earned points for utilizing regional materials for signicantly more than 20% of the projects total materials. Projects have also earned a point for reducing cement content by 40% compared to common practice. Thin Brick The use of an architecturally featured thin-brick nish adds a number of LEED benets in terms of site utilization, labor, energy, and sustainability. Unlike conventional masonry construction, thin brick does not require mixing of mortar, and does not result in water runoff that occurs with conventional masonry. Overall, thin brick is a cleaner process than conventional masonry, as there is no cement dust from the mixing operation, and it does not require sand piles. The construction site is also cleaner and safer because exterior fork lifts and scaffolding are eliminated. Additionally, there are savings to labor and energy as well. Manual labor for hand-laid product is eliminated, and since the thin brick is delivered with the precast, no additional trucking is required. Typically, 500 SF of thin brick can be laid in precast panels in less than one hour. The speed of application enables coordination of an accelerated delivery time. With thin brick, there is no delay to the construction schedule in waiting for the mason to complete work. Overall, thin brick is a cost-effective, LEED-friendly nish option that offers pleasing visual aesthetics, as well as signicant savings in labor, energy, and site utilization.
Credit 2 LEED Accredited Professional

98 LEED CONSIDERATIONS THE SHOCKEY PRECAST GROUP , WINCHESTER, VA WWW.SHOCKEYPRECAST.COM
Points Scoring Examples

POTENTIAL LEED POINTS FOR PRECAST CONCRETE PROJECTS Category Description Credit 5.1 Credit 5.2 Credit 7.1 Credit 7.2 Credit 1 Credit 1.1* Credit 1.2* Credit 2.1 Credit 2.2 Credit 4.1 Protect or Restore Habitat Maximize Open Space Heat Island Effect (Non-Roof) Heat Island Effect (Roof) Optimize Energy Performance Building Reuse: Maintain 75% of Existing Walls, Floors and Roof. Building Reuse: Maintain 95% of Existing Walls, Floors and Roof. Construction Waste Management: Divert 50% of all construction waste from landll. Construction Waste Management: Divert 75% of all construction waste from landll. Recycled Content: Materials with recycled content (Post-consumer + pre-consumer) constitute 10% of total value of project material. Recycled Content: Materials with recycled content (Post-consumer + pre-consumer) constitute 20% of total value of project material. Regional Materials: Materials that are extracted, processed and manufactured regionally (within 500 miles) constitute 10% of total building materials based on cost. Regional Materials: Materials that are extracted, processed and manufactured regionally (within 500 miles) constitute 20% of total building materials based on cost. Points 1 1 1 1 1-10 1 1 1 1 Sustainable Sites
Energy & Atmosphere Materials & Resources
Credit 4.2
Credit 5.1
Credit 5.2
IEQ (Indoor Environmental Quality) Credit 3.1 Credit 4.1 Credit 4.2 Construction IAQ Management Plan: During Construction Low Emitting Materials (Adhesives & Sealants) Low-Emitting Materials (Paints & Coatings) 1 1 1
Innovation & Design Process Credits 1.1-1.4 Exceptional Performance or Innovative Design Credit 2 LEED Accredited Professional Total Possible Points
* These points are obtainable only after a building has been constructed and is being reconsidered for other uses.
1-4 1 30
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RECENT CASE STUDIES

In this chapter, we will highlight several of The Shockey Precast Groups key total precast projects. We have explored these projects from the perspective of building envelope, design considerations, and typical components and connections. Chapter 6 offers detailed case studies on these projects to help the designer understand how total precast inuences total job performance. These structures represent the wide spectrum of possibilities that exist with the utilization of total precast as a building method, and we hope that they serve as inspiration for your next project.
Frederick County Public Safety Building

The Frederick County Public Safety Building was designed as a two-story structure to house the countys Sheriff and Fire and Rescue Departments. The building includes space for the Emergency Communications Center and Emergency Operations Center, as well as associated support spaces. An Ancillary Building is located behind the Safety building in the secure portion of the site. The Public Safety Building is approximately 61,500 square feet and the Ancillary Building is approximately 7,980 square feet.
The PSBs exterior, proportions, details and window arrangements were developed in a modern architectural style. The building is rectangular, with the second oor matching the rst oor footprint. The Emergency Communication Center portion of the building is shown on the exterior of the building by the curvilinear element located at the front corner of the structure. The low slope roof will drain to the rear of the building and a scupper system is used to remove rainwater from the roof. The exterior building materials are precast concrete wall panels with two complimentary color panels. The panels consist of a taupe accent panel at the stairs and projected areas of the building. A gold colored precast panel is used for the base areas and accented with a white precast
THE SHOCKEY PRECAST GROUP , WINCHESTER, VA WWW.SHOCKEYPRECAST.COM CASE STUDIES 101
base and fascia. Each panel received two nishes, a ne sand blast nish on the projected areas and a medium sand blast on the recessed areas. The structural system consists of precast double tees for oor and roof, including a nominal 4 topping on the second oor. The precast double tees bear on top of rectangular precast beams near the building centerline and the 8 thick structural precast wall panels at the perimeter. The precast beams span between 16 x 16 bull nosed architectural precast columns spaced no more than 32 on center. The main Operations Rooms for the Emergency Communications Center and Emergency Operations Center on the second oor required the slab to be dropped 8 by notching the double tee stems. The Public Safety Building consists of 291 precast pieces and the Ancillary Building consists of 39 precast pieces.
PROJECT DESCRIPTION Specialty Precast Engineer

The Shockey Precast Group Winchester, VA
Products Used
10DT32 with 2 ange 8 Interior wall panels 8 exterior load-bearing wall panels with architectural features and mixes Precast stair units 18 x 18 precast columns 18 x 36 ITB Architectural trim units (copings and cornices)
Owner
Frederick County, VA
General Contractor
Howard Shockey & Sons Winchester, VA
CASE HISTORY
In January 2006, the Shockey Precast Group (SPG), Howard Shockey & Sons (HSS), and Hayes, Seay, Mattern & Mattern, Inc. (HSMM) met to review the preliminary building sketches and overall building appearance for the Frederick County Public Safety Building. HSMMs project called for a tight schedule: from Notice to Proceed to Project Turnover, the project schedule was 17 months.
Architect
HSMM, Inc. Virginia Beach, VA
Engineer
HSMM, Inc. Virginia Beach, VA
Upon review, SPG proposed to HSMM to use a total precast system rather than a steel and masonry system. HSMM accepted the proposal. SPG decided to utilize Tekla Structures Precast, 3D BIM capabilities on the project, and created an initial 3D model for HSMMs review. The use of Tekla Structures visualization tools facilitated early MEP design decisions, and provided a simple
102 CASE STUDIES THE SHOCKEY PRECAST GROUP , WINCHESTER, VA WWW.SHOCKEYPRECAST.COM
method for addressing changes as the building concept continued to evolve. Following several meetings to review building panelization and precast color samples, it became apparent that the original anticipated start erection date of June 1 would be difcult to meet, and would require the majority of SPG engineering resources to meet the production/erection schedule. By May 2006, SPG began production of the double-tee precast concrete pieces, and it became apparent that engineering was unable to supply information to the plant quickly enough to maintain constant ow of production. Upon discussions with HSS, a revised erection start date of July 17, 2006 was established. By July 12th, SPG provided sealed 95% drawings and specications to HSS, allowing HSMM to issue 95% construction drawings. On July 17th Phase 1 erection began as planned, and continued until July 26th. On July 26th the crane was moved and began Phase 2 erection. Erection continued according to schedule, and on August 1st Phase 3 began. By August 14th plumbing and electric follow-on trades began work inside the building footprint. The crane was moved on August 18th to begin Phase 5 of erection. Erection was completed on August 22, 2006 three days ahead of schedule.
Key Benets of Utilizing Total Precast System vs. Conventional Construction:

Reduced erection time The Frederick County Public Safety building was erected in 5 weeks. The use of a total precast system resulted in a savings of 2 months to the overall schedule, as compared to a masonry/steel building. The overall schedule savings also translated to a savings on General Conditions for the General Contractor. Speed to market From Notice to Proceed to Project Turnover, the original project schedule was 17 months. By incorporating a total precast system and utilizing Tekla modeling, the actual project schedule was reduced to 12 months. Increased safety The decision to use a total precast system rather than steel and masonry meant a reduction of man hours in the eld, and an increase of man hours in a controlled manufacturing environment. Lower man hours in the eld translated to a decrease in the risk of injuries and lost time on the project. Sole source responsibility -- By putting responsibility for the superstructure in the hands of a single precaster, the need for coordination of submittals between several trades was eliminated. Speed to follow-on trades The rapid erection time associated with total precast systems meant that the Frederick County Public Safety Building was a totally enclosed structure ready for doors, windows, and follow on trades in just 5 weeks.
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Highmark Data Center

DESCRIPTION SHEET
A typical data center, often labeled a box of computers, usually conforms to a one-story big-box typology. The client for this project was seeking a building that could transcend this typology by also offering pleasing aetsthetics and a high-quality working environment for 40-80 potential employees. This 87,000-SF facility responds to these objectives and comprises a 50,000-SF box of computer space and MEP infrastructure benched into the landscape and wrapped with open ofce and support space. The computer infrastructure box does not require a view or natural light. The brick-andcurtain wall-clad support and ofce spaces wrap the south and west sides of the data center box were and exercise in breaking down in the composition even further, by creating interlocking and overlapping planes of curtain wall, metal panel and Norman brick. As the brick wraps the northern portion of the building, it dissolves into horizontal louvers that form a protective screen for the mechanical equipment yard. As the elevation continues east, this brick and louver skin dissipates, revealing precast concrete structure beneath. The selection of structural framing system for the project was subject to the common pro-con comparisons: cost, schedule, constructability, functionality, and aesthetics. Preliminary studies by the design team focused on a steel-framed building, an idea inuenced by proposed long spans and the need to accomodate atypical plan geometries and unique architectural facade conditions at certain building areas. With the clear design direction to utilize precast concrete panles for a substantial portion of the perimeter enclosure, the team also began to consider the use of a precast structural framing system. At the same time, the client retained a Construction Manager (CM) for the project, who quickly endorsed the all-precast option as a viable design solution.
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After meeting with local precast concrete suppliers and steel fabrcators, the CM developed cost estimates and construction schedules for both options. The result of these studies indicated that precast concrete was not only less costly, but that the all-precast building frame could be enclosed and completed in less time, largely due to the elimination of overlapping trades. The key to meeting the completion date was an aggressive fast-track schedule that required incorporating typically sequential tasks-design documents, precast component designs, preparation of precast shop drawings and precsast component fabrication-into a single seamless process. The precast concrete contract was awarded based on design documents that were on the order of 25% complete. The CM and design team developed a detailed list of clarications and directives to dene the scope of work required from the precast supplier. The design team also collaborated with the precast supplier, prioritizing the steps of the design process in order to facilitate the early creation of precast shop drawings and component fabrication. Ultimately, this collaborative process resulted in the completion of shop drawings and the production of substantial precast component quantities long before the completion of the nal 100% contract drawings for all design disciplines. Typical bay sizes for the 2-story facility are 50 x 40. Floor and roof framing consist of 13 - 4 wide double tees (DT) spanning 50, supported by inverted tee (IT) girders, all supported by 24 square precast concrete columns. DT and IT depths are 32/24 and 44/34 for the oor and roof levels, respectively. Concrete toppings of 3 and 2 for the oor and roof are provided for leveling and enhanced lateral diphragm strengths. Lateral loads due to wind and seismic forces
Construction progress photo, Highmark Data Center.
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are resisted by precast concrete shear walls, some of which also serve as the perimeter architectural facade. The structures design will accommodate a planned expansion along the east wall. Non-load bearing exterior wall panels along this face are not part of the lateral load-resisting system, and have been detailed to allow future removal and reuse in the expanded facility. Precast pre-stressed concrete construction is well suited for long span conditions, large bay sizes and high oor loading. In addition to the nancial benets that result from having fewer components that require fabrication and erection, the large bays also provide more open and exible oor layouts. This benet was particularly relevant to this project, where 50 x 40 bays maximized the efciency of server rack layouts at the upper level, and minimized interferences with the substantial amount of critical mechanical/electrical equipment and infrastructure occupying the lower level. Structural precast-framed structures are often subject to criticism that they do not easily accommodate atypical conditions and/or unique architectural expressions. However this project succeeds in dispelling that notion. The facilitys architectural design is highlighted by several stepped building massing forms and employs diverse exterior wall materials and plan geometries. While precast concrete wall panels wrap the central data center box, other perimeter and more visible facade conditions are clad with segments of brick with punched windows, curtain wall, and metal wall panel construction. The northwest corner of the administrative area is skewed in plan in two directions, cantilevers up to 15, and supports both curtain wall and metal wall panel construction. Shockey provided a monolithic all-precast rigid bent, with cantilever outrigger beams, to accomodate this unique framing condition. Because of their status as facilities whose critical operations cannot afford to be interrupted, data centers are frequently designed to accomodate upgraded wind loads. It is not uncommon for a data center to be designed to withstand a 150 mph wind load, particularly in or near hurricane or tornado-prone regions. To adhere to the clients desire for a robust facility and maintain a reasonable approach regarding excessive and nearly impossible wind speeds, this facility was designed to accomodate a 110-mph wind load as compared to the code-required 90-mph loading. The effects of this increase in wind speed accomodation lead to a 50% increase in design pressures, and a reduced recurrence interval risk, from 1-in-50 (as provided by the typical 90-mph code criteria) to 1-in-900. While the increase in design pressures is substantial, the all-precast structure was able to accommodate the enhanced loading with very little premium. Existing site conditions, including a sloping grade in an industrial park, also posed challenges for architects. The solution was a two-story building that reduced electrical and mechanical costs by stacking the program over the infrastructure that supports it - also allowing service entry to both oors on-grade. The space planning of the interior was choreographed to allow for tours of the building across a ramped glass hallway running between the Command Center and Data Service Center space, offering a commanding view of both at the same time. Since the facility is on a 24-7 schedule of operation, there was also an effort to maximize comfort for employees. In-house amenities include a tness center, break room, outdoor gathering area, adequate natural light and panoramic views of the surrounding landscape.
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FACT SHEET Category and Code

Industrial, MA (Manufacturing Facilities, High-tech)
Detailed project cost data, including total cost and cost of precast concrete package
At the clients request, the project cost is condential. The cost of the precast concrete package was between $2 and $2.5 million.
Primary use of structure

Data Center
Number and dimensions of precast, prestressed concrete components, GFRC components and/or architectural precast concrete components
Description 10 x 24 Double-Tees 10 x 32 Double-Tees 8 Precast Wall Panels 24 x 24 Precast Columns 24 x 34 Inverted-Tee Beams 24 x 44 Inverted-Tee 8 Prestressed, Insulated Walls Misc. Beams Total Pieces # Pieces 102 86 43 53 33 19 51 2 389 Quantity 46,520 SF 35, 168 SF 10,132 SF 1,737 LF 1,212 LF 630 LF 19, 064 SF 76 LF
Size and square footage of structure

87,000 SF total; 28,000 SF of raised oor data center
Structural material used

Precast double tees supported by precast inverted T girdles supported by precast columns with partial exterior precast wall panels
Products Used
10DT24 with 2 ange 10DT32 with 2 ange Screen Walls 24 x 24 Columns 24 x 34 ITB at Roof 24 x 44 ITB at Floor 8 Insulated Wall Panels with Architectural nish
Project timeline from design to occupancy, including precast manufacture and erection
November 2003 December 2003 January 2004 February 2004 March 2004 May 2004 June 2004 July 2004 August 2004 July 2005 November 2005 January 2006 Project Interview Project Kick-off Basis of Design Completed 10% design Completed Construction Documentation Began Permit Approved by West Hanover Township Sitework Began / CA Started Precast Erection Began Precast Erection Completed (5 weeks total) / Final Documentation Substantial Completion IT Migration Completed Grand Opening
Owner
Highmark Blue Shield Camp Hill, PA
General Contractor
Holder Construction Company Reston, VA
A/E Firm
RTKL Associates, Inc. Baltimore, MD
The Highmark Data Center is the 2006 recipient of PCI Design Awards in the categories of All Precast Facility, Best Manufacturing Facility, and Sustainability.
Specialty Precast Engineer

The Shockey Precast Group Winchester, VA
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Stoneleigh at Westelds Ofce Buildings I and II

Project Timeline
June 3, 2005 July 15, 2005 August 12, 2005 November 3, 2005 April 3, 2006 June 1, 2006 June 8, 2006 June 28, 2006 August 2, 2006 August 4, 2006 August 7, 2006 August 30, 2006 January 2007 February 2007 Start of Project Permit Drawings Ofce Building I Submittal Ofce Building I Submittal Returned Ofce Building I Erection Starts Ofce Building I Erection Complete Ofce Building II Erection Starts Ofce Building II Erection Complete Connector Building Erection Begins Connector Building Erection Complete Parking Structure Erection Start Parking Structure Erection Complete Turnover of Ofce Building I to Tenant Complete Finishing of Project
Case Study
The Shockey Precast Group sold the Stoneleigh at Westelds project as two, mirror-image, ve-story, 221,000 SF total precast ofce buildings and a single elevated level, 60,000 SF precast parking structure to the owner, Starco Properties, before a general contractor had been named. Both ofce buildings were designed to withstand three-second bursts of 90-mph wind speed, and a single-level connector building was designed to link the two ofce buildings. Stoneleigh at Westelds ofce buildings erection
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The project also included a single elevated level parking garage sited adjacent to the ofce buildings. The parking structure is constructed of precast concrete fabricated by Shockey at both its
Winchester and Fredericksburg plants. Shockey manufactured and erected 12 x 28 double tees with two-inch anges, 12 x 30 double tees with four-inch anges, 8 x 10 walls with architectural nish, and 24 x 24 columns. The total precast system utilized for this project also included the fabrication and erection of 24 x 36 and 24 x 42 beams, 10 and 18 pocketed load-bearing spandrels with architectural nish, and precast stair units. With 80 PSF plus 20 PSF live loads in ofce areas, the twin total precast structures feature exterior load-bearing architectural precast concrete spandrels cast with buff mix with a PROJECT FACTS light and medium sandblast. Stoneleigh at Westelds (Parcel 14A2) Corner of Westelds Blvd. and Park Each ofce building has a typical column, beam, and spandrel framing utilizing Meadow Drive 12 wide, 26 deep double tees with a two-inch ange that received a three-inch Chantilly, VA topping. Two stairs and a single elevator tower completed the central core of the building. Ribbon window units were secured to the spandrels and each end of Two Class-A 5-story ofce buildings the building had a bay curtain wall glazing system. The architectural exterior consisting of 221,000 SF. columns had an exterior bull-nose feature providing added aesthetic detail. 80 PSF + 20 PSF (partitions) live loads in ofce areas. The parking structure used a simple column, beam, and spandrel framing Designed for 3-second bursts of 90 system using pre-topped 30 double tees. Both ofce buildings and the parkMPH wind speed ing structure used two colors of architectural precast spandrels and two levels of Free-standing single elevated level sandblasted nish. parking structure (precast) adjacent buildings Engineerng on the project began in April 2005 and the precast products were 36 x 54 framing module, 14 oorerected in March 2006. In addition to The Shockey Precast Group, the project to-oor height team included SMCI of McLean, VA, contractor; Boggs & Partners of Annapo Exterior load-bearing spandrels cast lis, MD, architect; Cagley & Associates of Rockville, MD, engineer; and Starco with buff mix with a light and meProperties, owner. dium sandblast
Products Used
12DT28 with 2 ange 12DT30 with 4 ange 8 & 10 walls with architectural nish 24 x 24 Columns 24 x 36 ITB at 24 x 42 ITB at 10 & 18 pocketed load-bearing spandrels with architectural nish Precast stair units
Owner
Starco Properties VI, LLC Ft. Myer, VA
General Contractor
The Whiting-Turner Contracting Company, Baltimore, MD
Architect
Boggs & Partners Architects Annapolis, MD
Engineer
Cagley and Associates Rockville, MD Stoneleigh at Westelds elevation.
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SECTION 03 42 00 TOTAL PRECAST BUILDING
GUIDE SPECIFICATION General

1.1 SUMMARY
Section includes components for a total precast building, including but not limited to: 1. Structural precast concrete for: a. Columns b. Beams c. Spandrels d. Floor and Roof Double Tees e. Inverted Tee Beam f. Stair Riser Sections g. Wall Panels h. Flat Slabs i. Shear Walls 2. Architectural precast concrete for: a. Non-Structural Spandrels b. Non-Structural Walls c. Column Covers d. Coping/Sills 3. Caulking and Expansion Joints 4. Accessories and Supporting Devices B. Related Requirements: 1. Section 03 41 00 Precast Structural Concrete 2. Section 03 45 00 -- Precast Architectural Concrete 3. Section 07 92 01 Joint Sealants for interior 4. Section 07 92 02 Joint Sealants for exterior
1.2
REFERENCES
American Concrete Institute: 1. ACI 301 - Specications for Structural Concrete 2. ACI 318 - Building Code Requirements for Structural Concrete B. ASTM International: 1. ASTM A 36/A 36M - Standard Specication for Carbon Structural Steel
Shockey Precast Group Guide Spec
03 42 00
Total Precast Building 08/01/07

TPS SPECIFICATION 111
2. ASTM A 153/A 153M - Standard Specication for Zinc Coating (Hot-Dip) on Iron and Steel Hardware 3. ASTM A 185 - Standard Specication for Steel Welded Wire Fabric, Plain, for Concrete Reinforcement 4. ASTM A 416/A 416M - Standard Specication for Steel Strand, Uncoated Seven-Wire for Prestressed Concrete 5. ASTM A 497 - Standard Specication for Steel Welded Wire Fabric, Deformed, for Concrete Reinforcement 6. ASTM A 666 - Standard Specication for Austenitic Stainless Steel Sheet, Strip, Plate, and Flat Bar 7. ASTM A 706/A 706M - Standard Specication for Low-Alloy Steel Deformed and Plain Bars for Concrete Reinforcement 8. ASTM C 150 - Standard Specication for Portland Cement 9. ASTM E 119 - Standard Test Methods for Fire Tests of Building Construction and Materials 10. ASTM F1554 Grade 36 Anchor Bolts C. American Welding Society: 1. AWS D1.1 - Structural Welding Code - Steel 2. AWS D1.4 - Structural Welding Code - Reinforcing Steel 3. AWS D1.6 Structural Welding Code Stainless Steel D. Precast/Prestressed Concrete Institute: 1. PCI MNL-116 - Manual for Quality Control for Plants and Production of Structural Precast Concrete Products 2. PCI MNL 117 Manual for Quality Control for Plants and Production of Architectural Precast Concrete Products 3. PCI MNL-120 - PCI Design Handbook - Precast and Prestressed Concrete 4. PCI MNL-123 - Design and Typical Details of Connections for Precast and Prestressed Concrete 5. PCI MNL-127 PCI Committee Report Erectors Manual Standards and Guidelines for the Erection of Precast Concrete Products 6. PCI MNL 135 Tolerances for Precast and Prestressed Concrete Construction
1.3
DEFINITIONS
A. Fabrication Drawings: Documents used by the production facility to manufacture the precast components. Sometimes referred to as Shop Drawings. Information included: 1. Required dimensional information 2. Description and location on all inserts, bearing plates, anchors and reinforcement materials required to manufacture, transport, and erect the precast component 3. Finish requirements for each component 4. Handling, storage and shipping instructions 5. Provided as an informational submittal only B. Erection Drawings: Documents providing the assembly placement of precast components on the job site. Erection Drawings are reviewed and sealed by a Professional Engineer. Information included: 1. Plans and elevations locating and dimensioning all precast components. Each precast component is individually identied. 2. Sections and details showing connections, openings, blockouts, and cast-in items and their relationship to the structure. 3. Description of all loose and cast-in hardware for making connections.

112 TPS SPECIFICATION
03 42 00
C. Construction Plan: A management plan for the sequence of assembly of the precast components of the project. This plan includes: 1. Access plan for crane and transport of precast components. 2. Erection sequence by loads being shipped. 3. Erection block plan outlining the sequence of erection activity. 4. Specic erection criteria required for the particular project. 5. Project-specic construction stability plan that outlines any additional erection bracing that may be required. 6. Technical data sheet on grout used for the project. 7. Erection tolerances for the project. D. Field-Use Erection Drawings: The erection drawings with any modications made during the approval process that are distributed prior to actual erection of the project. E. Control Number: A unique identication of each precast component for a project. F. Piece Mark: A component identication of a precast element on a project. Similar pieces can have the same Piece Mark but each will have a unique Control Number. G. CIP: Cast-In-Place Concrete H. Architectural Features: Where nal appearance or form of precast components require the use of colored aggregate, pigmented concrete mix or surface textures such as sandblasting, water wash, etched nishes or thin brick. I. BIF: Bottom in form indicates the surface of precast that will be in the bottom of the form during casting. J. SIF: Side in form indicates the surface of the precast that will be in the side of the form during casting by built-up rails. K. TIF: Top in form indicates the top exposed surface during casting. L. Structural Precast Products: Precast products that are load-bearing members taking loads of the structure down to the foundation. Structural products may or may not have architectural features. M. Architectural Precast Products: Architecturally featured members that are not loadbearing
1.4
ADMINISTRATIVE REQUIREMENTS
A. Coordination 1. Coordinate the Work of framing components not pre-tensioned but associated with the Work of this section. 2. Coordinate cutting, drilling or coring in precast members with the manufacturer. 3. Coordinate all precast openings or penetrations greater than 10 inches in any dimension with the manufacturer prior to submittal of Erection Drawings. B. Pre-installation meetings 1. Convene minimum one week prior to commencing the onsite work of this section. 2. Coordinate the sequence of installation with foundation and supporting elements in place with precast items to be delivered.
03 42 00

C. Site Survey: Provide a site survey to verify eld dimensions and tolerances a minimum of 2 weeks prior to delivery of precast units for installation.
1.5
SUBMITTALS
Action Submittals: Provide for review and approval. 1. Erection Drawings: Indicate layout, unit locations, unit identication marks, connection details, dimensions, openings, and relationship to adjacent materials and conformance with the requirements of the Contract Documents and sealed by professional engineer. Provide coordination information for items required to be embedded in adjacent materials. 2. Design Calculations: Submit design data reports indicating calculations for loadings and stresses of fabricated precast components, connections, and reinforcement. Calculations shall be prepared by Professional Engineer experienced in precast concrete design. Samples: Submit three samples 12 x12 inch (304.8 x 304.8 mm) in size illustrating surface nish treatment of architectural featured component. 4. Mockup: Provide access to a mockup panel at the precast manufacturing plant for approval by the Architect for color and texture. The approved mockup shall be the control standard for color and texture. Informational Submittals Mix Design: Provide the concrete design mix with certication regarding compliance with requirements of the Contract Documents. 2. Field Use Erection Drawings: Submit eld use erection drawings incorporating comments from approved Erection Drawings. 3. Construction Plan: Submit prior to the pre-installation meeting, a construction plan, including calculations and details for guying, staying and shoring precast elements to assure structural stability during the erection phase. Provide for the removal, replacement, and relocation of guying, bracing and shoring required until all permanent structural connections are completed. C. Closeout Submittals 1. Provide Manufacturers Warranty letter.
1.6
QUALITY ASSURANCE
A. Perform precast work in accordance with requirements of PCI MNL-116 for structural work and PCI MNL-117 for Architectural precast work. B. All product and connection design shall be in accordance with PCI MNL-123 and PCI MNL-120. C. Fire Rated [Wall] [Floor] [Roof ] Construction: Rating as indicated on Contract Documents. D. Source Quality Performance Testing: Provide for tests for all precast concrete work in conformance with PCI Plant Certication requirements. Use certied test equipment, and unless otherwise specied, conform with: 1. Manual For Quality Control For Plants and Production of Precast and Prestressed Concrete Products, PCI MNL-116 (latest edition) 2. Manual For Quality Control For Plants and Production of Architectural Precast Concrete Products, PCI MNL-117 (latest edition) 3. PCI Design Handbook, Latest Edition. 4. ACI 318 for the Building Code Requirements for Reinforced Concrete (latest edition)

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E. Mockup Control Sample Unit: Provide a mock up panel at the plant, 4 feet by 4 feet in size, for quality comparison of nished unit to an approved appearance sample for color and texture. F. The plant quality control records and inspection procedures for this project shall be available for review, verication and in-plant inspection by an independent testing agent or the Architect/Engineer.
1.7
QUALIFICATIONS
A. Fabricator: Company certied by the Prestressed Concrete Institute (PCI) Plant Certication Program with an in-house engineering department managed by a registered professional engineer. B. Precast Engineer: Design precast concrete members under direct supervision of Professional Engineer experienced in precast design and licensed in the state of the project. C. Erector: Company with experience in the erection of precast units similar to those required for this project and shall be a Qualied Erector under the PCI Field Certication Program. Welder: Qualied in accordance with AWS D1.1, AWS D1.4, and AWS D1.6
1.8
DELIVERY, STORAGE, AND HANDLING
A. Lift and support precast concrete members during manufacturing, yarding, transporting and erection operations only from identied support points with suitable lifting and handling devices. B. Lifting inserts will have a minimum safety factor of 4. Reusable lifting hardware and rigging will have a minimum safety factor of 5. C. Lifting or Handling Devices: Capable of supporting member in positions anticipated during manufacture, storage, transportation, and erection. D. Storage: 1. Protect members to prevent staining, chipping, or spalling of concrete. Store members off the ground on dunnage materials as recommended by fabricator. 2. Place all units so that identication marks are readable. 3. Stack so that lifting devices are accessible and undamaged. E. Mark each member with date of production, job number, control number, and piece mark referenced from Erection Drawings.
1.9
WARRANTY
A. Provide Manufacturers Warranty for a 1-year period. PART 2 PRODUCTS
2.1
FABRICATORS
Fabricators: 1. Shockey Precast Group, Winchester Virginia, Tel: (540) 667-7700, website www.shockeyprecast.com.
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2.2
DESIGN REQUIREMENTS
General: The project, as shown on the drawings, including component dimensions and connection congurations, provides the requirements for the development of the design documents. Design shall include consideration for customary stresses incurred in factory precasting, transporting, and erecting. The design, manufacturing, transportation and erection process shall be compatible with the requirements of the Contract Documents. B. Design Criteria: 1. Design all ledges, haunches, bearing areas, and connections as recommended in PCI Design Handbook. Haunches, dapped end bearings and connections without redundant means of load transfer are considered critical. 2. Minimum reinforcing for all precast prestressed concrete and precast reinforced concrete shall be in accordance with ACI 318. Analysis of prestressed components will include a check of the shear reinforcing requirements at .1L, .2L, .25L and .3L, where L is the component length. C. Floor Level Topping Slab: Topping slab shall be designed as the lateral force transferring diaphragm. Minimum compressive strength of topping slab shall be 4,000 psi. 1. Precast specialty engineer shall be responsible for the design and detailing of the topping slab and reinforcement in topping slab. This responsibility includes concrete thickness and strength, as well as reinforcement quantity, type, and layout. 2. The Engineer of Record (EOR), with assistance from the precast specialty engineer, shall be responsible for reviewing and approving the topping mix design for compatibility with the precast specialty engineers intent. 3. Construction joint locations shall be provided by the specialty engineer. Drawings depicting joint locations shall be provided by the specialty engineer to the General Contractor. 4. General Contractor shall be responsible for materials and labor for topping slab installation. Quality control for topping slab installation shall be provided by General Contractor or the Owners independent testing agency. D. Modications: Submit all proposed modications to the project designs represented on the drawings with complete design calculations and drawings, prepared and signed by a licensed professional engineer for review and approval. Maximum Allowable Deection: Per ACI 318-9.5 - Control of Deections Seismic Design: Design and detail elements and connections to resist seismic force in accordance with code requirements and ACI 318 for the following: 1. As specied by Contract Documents. G. Design members exposed to weather to allow movement of components without damage, failure of joint seals, undue stress on fasteners or other detrimental effects, when subject to seasonal or cyclic day/night temperature ranges. H. Design system to accommodate construction tolerances, deection of other building structural members and clearances of intended openings. I. Calculate structural properties of framing members in accordance with ACI 318.
2.3
MATERIALS
A. Concrete Materials: As appropriate to design requirements and PCI MNL-116. 1. Cement: Gray Portland, conforming to ASTM C 150 Type I or III.

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2. Cement: White Portland, conforming to ASTM C150 Type I (for architectural mixes). 3. Aggregates: ASTM C 33 4. Air-entraining admixtures: ASTM C 260 5. Water-reducing, Retarding, Accelerating Admixtures: ASTM C 494 6. Pigments: Non-fading, lime-resistant pigments B. Concrete Mix Design: ACI 318, Chapter 5, using standard deviation calculations in accordance with section 5.3.1.1 or 5.3.1.2. 1. The concrete mix designs will conform to the following requirements: Structural concrete: Columns, Walls, Stairs, Spandrel Beams Strength of Concrete 5000 psi Water-cement ratio - .42 + .00/-.05 Air Content 5.5% +/- 1.5% Structural concrete: Double Tees, Beams Strength of Concrete 6000 psi Water-cement ratio .40 + .00/-.03 Air content 5.5% +/- 1.5% Self-Consolidating Concrete (SCC) Strength of Concrete 6000 psi Water-cement ratio .38+ .00/-.05 Air content 5.5% +/- 1.5% Architectural concrete: Strength of Concrete 5000 psi Water-cement ratio .44 + .00/-.05 Air content 5.5% +/- 1.5% 2. Separate face mix and backing mix: a. Face mix: Minimum 5,000 psi, 28 day strength, air entrained to 5 to 7 percent [in accordance with [ACI 301] [ACI 318]. b. Backing mix: Same aggregate-cement ratio as face mix; achieve 28 day compressive strength of 5,000 psi. C. Batching concrete: 1. The concrete batching plant will be in conformance with ASTM C 94 and will be certied by the National Ready Mixed Concrete Association. Volumetric batching of concrete will not be permitted. All measurements of the various components will be by weight and will be accurate (within the most recent tolerance limits of ASTM C 94). 2. The use of calcium chloride or admixtures containing chloride ions or other salts is not permitted.
2.4
REINFORCING AND CONNECTION MATERIALS
A. General: Provide all reinforcement, accessory and connection materials required for a complete installation as indicated on the approved drawings. Pour strip reinforcement to be supplied and installed by others unless specied. Provide grouting as required for design bearing. B. Reinforcing Bars: ASTM A 615, Grade 60. Reinforcing used to fabricate embedded parts or connections by welding will be ASTM A 706.
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C. Welded anchor studs: AWS D1.1 D. Prestressing Strand: ASTM A 416, 270,000 psi minimum ultimate strength, uncoated, 7-wire, low relaxation. E. Anchor Bolts: ASTM F 1554 Grade 36 F. Welded Wire Fabric: ASTM A 185 (plain steel) or ASTM A 497 (deformed steel); in at sheets; unnished. G. Carbon Fiber Reinforcement: C-GRID as manufactured by Chomarat North America. H. Tensioning Steel Tendons: ASTM A 416/A 416M Grade 270K of sufcient strength commensurate with member design. I. Rod Anchor bars: Dayton/Superior High Strength Coil Rod, or approved equal. J. Supports for Reinforcement for Exposed-to-View Concrete: CRSI Class 1, plastic protected legs.
2.5
ACCESSORIES
Connecting and Supporting Devices: 1. ASTM A 36/A 36M carbon steel, Plates, angles, items cast into concrete [or] [items connected to steel framing members,] inserts conforming to PCI MNL-123; hot-dip galvanized in accordance with ASTM A 153/A 153M. Surfaces requiring eld welding shall be ZRC painted. 2. ASTM A 666 Type 302 or 304 stainless steel, Tee-to-Tee ange connections conforming to PCI MNL-123. 3. Anchor Bolts: ASTM F 1554 Grade 36 Grout: Non-shrink, non-staining, minimum yield strength of 5,000 psi at 28 days. Bearing Pads: 1. Standard Bearing Pad: Rubber pad composed of homogeneous blend of ozone-resistant rubber elastomer and high strength random synthetic ber cords; Surface hardness of 75 Shore A durometer +/- 5 percent; Compression, 8000 psi; MASTICORD as manufactured by JVI Inc. or approved equal. 2. Laminated Fabric-rubber Pads: Preformed, unused synthetic bers and new unvulcanized rubber. Surface hardness of 80 Shore A durometer +/- 10%. (Capralon or approved equal). 3. Expansion Bearing Pads: Assemblies consisting of lower and upper components. Dynalon or approved equal. a. The upper component: An assembly of a sheet of stainless (14 gage minimum) with a minimum 2B mill nish. Sized larger than the lower element by a minimum of 1/2 inch in each direction. b. The lower element: An assembly of a Standard Bearing pad, with a stainless steel support plate and a bonded contact layer of PTFE (Teon). D. Shims: Steel, ASTM A 36; or engineered multipolymer plastic material, compressive strength of 8000 psi; Korolath, or an approved equal. E. Mechanical Splice for Future Expansion Column and Wall Reinforcing Anchorage: Erico Lenton or NMB Splice Sleeve.

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F. Double Tee Flange-to-Flange Shear Connectors: Per PCI Design Handbook, Sixth Edition, Figure 3.8.1.2.B. G. Bolts, Nuts and Washers: ASTM A 307 High-strength steel type recommended for structural steel joints; Corrosion resistant chromium-nickel type. H. Prime Paint: (ZRC) Zinc rich alkyd type coating.
2.6
FABRICATION
A. Fabrication procedure for all precast concrete products to conform to ACI 318. B. Fabrication procedure for precast concrete products to conform to PCI MNL-116 for Structural products; PCI MNL-117 for Architectural precast concrete products. C. Maintain plant records and quality control program during production of precast members. Make records available upon request. D. Use rigid molds, constructed to maintain precast unit uniform in shape, size, and nish.
E. Ensure reinforcing steel, anchors, inserts, plates, angles, and other cast-in items are embedded and located as indicated on erection drawings. Clean surfaces of all embedded items of rust, scale, grease, and foreign matter. F. Hardware supplied by other trades shall be furnished to the fabricator fully assembled and tagged for location a minimum of 30 days prior to scheduled production. G. Fabricate required openings with dimension larger than 10 inches (250 mm) in diameter or larger for rectangular openings as shown and approved on erection drawings. Provide openings in Tee stems for running electrical conduit as coordinated with approved shop drawings; and embed accessories provided by other Sections, at indicated locations. H. Tension reinforcement tendons as required to achieve design load criteria. I. Ends at Stressing Tendons: Coat the exposed ends of prestressing strands in all prestressed members with a bitumastic coating; Sonneborn Hydrocide 700 or approved equal. Recess exterior exposed to view ends of tendons and ll with grout after coating strands. J. Weld steel fabrications in accordance with AWS D1.1. Weld reinforcing steel in accordance with AWS D1.4. Welding processes shall not reduce the cross-sectional area of the concrete reinforcement. Do not tack weld reinforcing. Paint all eld welds with ZRC. K. Mark each piece of precast concrete for identication and record the date of casting. Marks will be placed so the nal appearance of the product is not impaired. L. Provide free access by the Architect/Engineer to all parts of the manufacturing facility. M. Minor patching in plant is acceptable, providing structural adequacy and appearance of units is not impaired. N. Place recessed ashing reglets continuous and straight.
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O. Lifting devices exposed to view in nal construction will be cut off and patched to match surrounding surface. Lifting devices interfacing with other trades shall be lled with non-shrink grout only. Lifting devices not exposed to view or interfacing with other materials will be cut off only.
2.7
FINISHES
A. Provide nishes as indicated on the nishes schedule listed below. Double Tees Floor: Top surface shall be transverse raked to 0.25 depth minimum to insure bond of topping. Roof: Top surface shall be oat nished with a magnesium oat. SIF, BIF and edges: Standard form nish Depressor holes: Shall be lled with non-shrink, non-staining grout to match surrounding surfaces. Inverted T-Beams Top surfaces to receive CIP topping: Top surface shall be transverse raked to 0.25 depth minimum to insure bond of topping. Top surfaces not receiving CIP topping: Top surface shall receive rough broom nish that shall not exceed a depth of 0.25 and that shall be perpendicular to the length of the beam. SIF, BIF and edges: Standard form nish. Columns For non-architecturally nished columns: SIF and BIF shall be standard form nish. TIF nish shall be steel trowel. For architecturally nished columns: SIF and BIF surfaces shall receive nish as prescribed by approved architectural sample. TIF nish shall be steel trowel. Spandrels TIF surface: a. Exposed-to-view: Shall receive a steel trowel nish. b. Not exposed to view: Shall receive a smooth magnesium oat nish. SIF and BIF surfaces: Standard form nish. For spandrels that require architectural nish: SIF and BIF will receive nish as prescribed by approved architectural sample. Walls TIF surface: a. Exposed-to-view: Shall receive a steel trowel nish. b. Not exposed to view: Shall receive a smooth magnesium oat nish. SIF and BIF surfaces: Standard form nish. For walls that require architectural nish: SIF (where required) and BIF will receive nish as prescribed by approved architectural sample. Stairs Top surface in nal construction: Rough broom nish not to exceed a depth of 0.25 or sandblast nish to provide non-slip surface. SIF and BIF surfaces: Standard form nish. Flat Slabs

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Flat slab areas of CIP concrete topping: Top surface shall be transverse raked to 0.25 depth minimum to insure bond of topping. Flat slab areas without CIP concrete topping: Top surface shall receive rough broom nish that shall not exceed a depth of 0.25. SIF and BIF surfaces: Standard form nish.
2.8
FABRICATION TOLERANCES
Structural precast concrete products to conform to PCI MNL-116 (latest edition). 1. Exception: Double tee lengths +1/4 inches/- 3/4 inches. B. Architectural precast concrete products to conform to PCI MNL-117 (latest edition).
2.9
SOURCE QUALITY CONTROL AND TESTS
A. Test and analyze Structural precast concrete in accordance with PCI MNL-116 (latest edition). B.Test and analyze Architectural precast concrete in accordance with PCI MNL-117 (latest edition).
PART 3 EXECUTION 3.1 EXAMINATION
A. A minimum of 2 weeks prior to scheduled delivery of precast materials, verify supporting work and site conditions are ready to receive work and eld measurements are as indicated on eld use erection drawings. B. General Contractor shall provide to fabricator verication that supporting structure has met or exceeded the design requirements of the precast system design as required by PCI guidelines and Contract Documents. Support requirements shall include but not be limited to: 1. Field Placed Bearing Walls or Footings: Provide true level bearing surfaces with elevations of +/- 1/2 inch unless shown otherwise on the Drawings. 2. Accurate placement and alignment of anchor bolts, plates, or dowels in CIP column footings, beams, wall footings, and other eld placed supporting elements. 3. CIP Concrete supporting structure has met design strength requirements as specied.
3.2 3.3
PREPARATION ERECTION
A. Prepare support equipment for erection procedure.
A. Install and secure precast units as shown on the Contract Documents and as indicated by the eld erection drawings in conformance with PCI MNL 127. B. Erect members without damage to structural capacity, shape, or nish. Replace or repair damaged members. C. Align and maintain uniform horizontal and vertical joints, as erection progresses. D. Maintain temporary bracing in place until nal support is provided. E. Provide temporary lateral support to prevent bowing, twisting, or warping of members.
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F. Adjust differential camber between precast members to tolerance before nal attachment. G. Secure units in place. Perform welding in accordance with AWS D1.1, and AWS D1.6 for stainless.
3.4
ERECTION TOLERANCES
A. Erect members level and plumb within allowable tolerances. Conform to PCI MNL-135 Tolerances for Precast and Prestressed Concrete Construction. C. When members cannot be adjusted to conform to design or tolerance criteria, consult with Architect/Engineer. Execute modications as directed by Architect/Engineer.
3.5
FIELD QUALITY CONTROL
A. Welding: Inspect welds in accordance with AWS D1.1, AWS D1.4, and AWS D1.6 as appropriate.
3.6
PROTECTION OF INSTALLED CONSTRUCTION
A. Protect members from damage caused by eld welding or erection operations. B. Use non-combustible shields during welding operations to protect adjacent Work.
3.7
CLEANING
A. Clean weld marks, dirt, or blemishes from surface of exposed members. B. Remove all debris and surplus materials associated with this scope of work from the premises.

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GLOSSARY
A
Abrasive nosing -a non-skid metal unit which is cast into the nose of a precast stair panel. Addendum - a supplement to specications or contract drawings issued prior to the execution of the construction contract. Admixture - a material other than water, aggregates, and cement used as an ingredient of concrete or grout to impart special characteristics. Admixture, air entraining a material added to the concrete for the purpose of entraining minute bubbles of air in the concrete during mixing and thus improving the durability of concrete exposed to cyclical freezing and thawing in the presence of moisture. A frame an A-Shaped frame used to support panels on at bed trucks during shipping. part of a connection (2) any item cast into or pre-afxed to the structure for the purpose of receiving a connection Approval acceptance of the Precasters drawings by the Architect, Engineer of Record, and General Contractor indicating that all building conditions and dimensions shown are correct and nal. Architectural precast concrete any precast concrete unit of special or occasionally standard shape that through application or nish, shape, color, or texture contributes to the architectural form and nished effect of the structure; units may be structural or decorative, and may be conventionally reinforced or prestressed. Assembly a set of parts arranged into one unit.
B
Aggregate natural occurring, processed or manufactured inorganic particles which are mixed with Portland cement and water to produce concrete; normally comprises 60 to 80 percent of the total volume of concrete. Aircraft cable multi-strand steel cable, in loop form, cast in precast panels for handling purposes; cable is more exible than prestressing strand. Air entrainment an increase in the amount of air in a concrete mix through the use of an air-entraining admixture (see admixture, air entraining); air entrained concrete displays increased workability and cohesiveness. Air pocket pits (entrapped air or water bubbles) in the form faces of a panel caused by improper consolidation or inadequate draft. Alignment face face of a wall panel which is to be set in alignment with the face of adjacent panels. Anchor (1) headed studs, deformed studs, straps, rebar, etc. welded to steel angels or plates and embedded in concrete for use as Backup material material used to limit the depth of the sealant in panel joints. Backup mix the concrete cast into the mold as a ller behind a thin layer of the more expensive face mix Bagtie thin gage wire ties (generally No. 16, 15, or 14 gage) used to fasten reinforcing bars together at intersections. Bar chair a non-corrosive, rigid device used to support and/or hold reinforcing bars at a given distance from the form face before and during concreting. Base plate a steel plate anchored to the bottom of a precast unit for the purpose of fasting it to the foundation. Batch the amount of concrete produced in one mixing operation. Beam pocket opening in a vertical member in which a beam is to rest. Bearing area - the surface in square inches
which comes into contact with a vertical load transferring member. Bearing pad a pad, usually neoprene, which is placed between a member and its support. Bearing plate a steel- or Teon-coated plate placed between a member and its support. Bill of materials material list for individual project Bleed hole a hold in a plate or angle which is provided solely to release entrapped air or water during concrete placing operation. Bleeding a form of segregation in which some of the water in a mix rises to the surface of freshly placed concrete; also know as water gain. Blocking the shims required to level and/or plumb a unit in its proper position. Blockout to form a hole, or reduce the height or width of a panel by afxing material to the form (space within a form in which concrete is not to be placed). Bond breaker a substance placed on a material to percent it from bonding to the concrete, or between a face material such as natural stone and concrete backup. Bowing the deection of a vertical panel in a single plane. Bulkhead a vertical partition in the form blocking fresh concrete from a section of the form; divides a continuous casting bed into given unit lengths. Bundling placing several parallel elements of reinforcement in contract with each other.
to avoid deection under load to below a dened line of nished product. Cast to place concrete (in plastic state) into a form. Cast-in cat integrally with a concrete unit; not stabbed in after casting. Cast-in-place concrete which is placed in the eld. Cast stone precast concrete whose nish resembles that of cut or polished stone. Caulking an elastomeric sealant used to ll panel joints thus sealing a building from the elements. Chamfer a beveled corner or edge which is formed in concrete work by placing a three-cornered piece of wood (cant strip or skew back) in the form corner. Chamfer strip triangular or cured insert placed inside corner of form to produce rounded or beveled corner; also called llet, cant strip, skew back. Clearance the distance between two surfaced. Clear span the distance between the inside edges of the bearing surfaces of two supporting members. Cold Joint a joint necessitated by several casting stages but designed and executed to allow the separate components to appear and perform as one homogeneous unit; term only applies when the rst casting is allowed to harden prior to placing the second. Column an element used primarily to support axial compressive loads and with a height at least three times its smallest lateral dimension. Column cover a precast panel which covers one or more sides of a column which would otherwise be exposed. Composite construction a type of construction wherein the oor slab is fastened to the beams in such a manner that they act together as a more efcient member in carrying live loads.
C
Camber (1) the upward deection which occurs in prestressed concrete elements due to the net bending resulting from stressing forces and selfweight. It specically does not include dimensional inaccuracies due to errors in manufacture, improper bearings, or other deciencies in construction; (2) a built-in upward curvature in some forms for precast concrete, other than prestressed,
Concrete a mixture of portland cement, ne aggregate, coarse aggregate, and water. Concrete, structural lightweight concrete that has a 28-day compressive strength in excess of 2,500 PSI and an air-dry unit weight of less than 115 PCF,; a lightweight concrete without natural sand is termed all-lightweight concrete and lightweight concrete in which all ne aggregate consists of normal weight sand is termed sandlightweight concrete. Concrete cover the clear distance from the face of the concrete to the reinforcing steel. Consolidation the use of hand tools, vibrators, or nishing machines during the casting process to eliminate voids, other than entrained air, and to provide a dense concrete, good bond with reinforcement, and a smooth surface. Coping a panel which forms the top of a wall and seals it form the elements. Corbel steel or reinforced concrete bracket which protrudes from a column or wall panel to provide support for another member or take support from an adjacent part of structure. Cornice panel which ts under a ceiling or projecting roof. Curtain wall precast wall panels which when in place may form window frames and interior/exterior wall construction, but support no loads from building.
E
Elongation in prestressed work, the difference between a strands initial length and its length after stressing. Engineer of record - engineer who creates original building design and is responsible for the design. Erection the placing of precast units into their respective positions in the structure. Expansion bolt or anchor an expandable device made of metal inserted into a drilled hole in hardened concrete that grips concrete by wedging action when the nut or head is rotated.
F
Fabrication actual work on reinforcing bars or hardware such as cutting, bending, and assembly. Face the surface of a panel. Face mix the concrete at the exposed face of a concrete unit; used for specic appearance reasons. False joint scoring on the face of a precast unit; used for aesthetic or weathering purposes and normally made to stimulate an actual joint. Fascia the outside horizontal panel on the edge of a roof or overhang. Fenestration the design and placing of windows in a building. Finish - treatment or texture given to concrete surfaces. Form a temporary receptacle which receives concrete and dictates a units shape. It can be made of wood or steel, but requires not pattern or positive. Form liner molded sheet which when afxed to a form gives the panel a special nish treatment; liners are made of rubber, plastic, wood, etc. Form release agent a substance applied to the forms for the purpose of preventing bond between the form and the concrete cast in it.
D
Deection the distance a structural member moves from its normal position when subjected to a load. Draft the slope of concrete surface in relation to the direction in which the precast element is withdrawn from the mold; it is provided to facilitate stripping with a minimum of mold breakdown. Drip a projecting n or groove at the outer edge of a sill, projecting horizontal wall element or soft, designed to interrupt the ow of rainwater downward over the wall or inward across the soft; drips are normally used only on units having smooth or lightly exposed nish.
G
Galvanize- to coat with rust resistant zinc by spraying, dipping, or electrolytic disposition.
precast units. Inserts are machine or coil-threaded to receive a bolt or slotted to receive a bolt head.
J
Gradation the sizing of granular materials. For concrete materials, usually expressed in terms of cumulative percentages larger or smaller than each of a series of sieve openings or the percentages between certain ranges of sieve openings. Grout a mortar type mixture which is hand packed or applied under pressure in such a consistency as to ensure complete lling of all voids. The usual proportions of a grout mix are one (1) part of cement to three (3) parts of well-graded sand by weight with water content adjusted so that a mass of grout squeezed in the hand remains its shape. Joint The space between two adjacent erected panels.
K
Key a continuous or semi-continuous slot in concrete to receive grout, leveling blocks, or dowels.
L
Lifting device an assembly used in handling or erection of precast panels.
H
Hardware a collective term applied to items used in connecting precast units or attaching or accommodating adjacent materials or equipment. Hardware is normally divided into three categories: Contractors Hardware items to be placed on or in the structure in order to receive the precast concrete units: e.g., anchor bolts, angels, or plates with suitable anchors. Plant Hardware items to be embedded in the concrete units themselves, either for connections and precast erectors work, or for other trades, such as mechanical, plumbing, glazing, miscellaneous iron, masonry, or roong trades. Erection Hardware all loose hardware necessary for the installation of the precast concrete units. Honeycomb a coarse stony concrete surface with voids lacking in nes; some probable causes are congested reinforcement, narrow section, insufcient nes, loss of mortar, and inadequate consolidation. Lift point predetermined points from which a panel is to be lifted. Load bearing supporting the dead and live load of other members. Load-bearing precast units precast units which form an integral part of the building structure and which are essential to its stability.
M
Mark Number the individual identifying mark assigned to each precast unit predetermining its position in the building. Master Mold a mold which allows a maximum number of casts per project; units cast in such molds need not to be identical, provided the changes in the units can be accomplished simply as pre-engineered mold modications. Matrix the portion of the concrete mix containing only the cement and ne aggregates (sand). Maximum size aggregate aggregate whose largest particle size is present in sufcient quantity to affect the physical properties on concrete; generally designed by the sieve size on which the maximum amount permitted to be retained is 5 or 10 percent by weight.
I
Insert a connecting or handling device cast into
Mitre the edge of a panel that has been beveled to an angle other than 90 degrees. Mockup a section of a wall or other assembly built full size, or to scale, for purposes of testing performance, studying construction details, or judging appearance. Module a repeating or reoccurring dimension or detail. Mold the cavity or surface against which fresh concrete is cast to give it a desired shape; sometimes used interchangeably with form but made of berglass or concrete; a pattern or positive is built rst and the mold is overlayed. Mortar a mixture of cement, sand, and water; when used in masonry construction, the mixture may contain masonry cement, or portland cement with lime or other admixtures which may produce greater degrees of plasticity and/or durability. Mullion a vertical precast unit appearing between windows and/or doors. Muntin horizontal precast appearing between windows and/or doors.
P
Panel an individual precast unit Parapet that part of the wall that extends able the roof line. Patch to repair a supercially damaged panel by lling the damaged area with concrete of matching color and texture. Pier a short column used as a foundation member in building construction. Pilaster column partially or completely embedded in a wall, or a portion of a wall enlarged to serve as a column. Plate a sheet of metal having a thickness of 1/8 inch or greater. Plate washer a special washer prefabricated from steel plate. Poured in place (see cast-in-place) Precast concrete a plain reinforced or prestressed concrete element cast in other than its nal position in the structure; precast concrete can be architectural or structural. Precast engineer the structural engineer authorized by the manufacturer to ensure the adequacy of the structural aspects of the drawings, manufacture, and installation for which the manufacturer is responsible. Preliminary - not completely nalized and reviewed. Prestressed concrete - concrete in which there have been introduced internal stresses of such magnitude and distribution that the stresses resulting from loads are counteracted to a desired degree. Prestressing bed - the platform and abutments needed to support the forms and maintain the tendons in a stressed condition during placing and curing of the concrete. Pretensioning a method of prestressing concrete whereby the tendons are elongated, anchored while the concrete in the member is cast, and released when the concrete is strong enough to receive the stresses from the tendon through bond.
N
Nailer a beveled wooden strip cast into a precast panel for the purpose of nailing ashing or roong to it. The use of such material in concrete is not recommended. Neoprene a synthetic rubber bearing pad. Normal weight concrete concrete for which density is not a controlling attribute and usually having unit weights in the range of 135 to 160 lbs. per cubic foot. Nosing a projection such as that of the tread of a stair over the riser.
O
Overhang the projecting area of a roof or upper story beyond the wall of the lower part.
Q
Quirk mitre a corner formed by two chamfered panels.
Rustication strip a strip of wood or other material attached to a form surface to produce a groove or rustication in the concrete.
S R
Rebar abbreviated term for reinforcing bar. Reinforced concrete concrete containing reinforcement, including prestressing steel, and designed on the assumption that the two materials act together in resisting forces. Reinforcement mesh, strand, or post-tensioning cables embedded in concrete and located in such a manner that the metal and the concrete act together in resisting loads. Release (1) the time at which the prestressed strands are severed prior to removing the prestressed units from the forms; (2) submittal of drawings; (3) stripping of precast panel Release agent (see form release agent) Retarder an admixture which delays the setting of cement paste and therefore of concrete Retarder, surface a material used to retard or prevent the hardening of the cement paste on a concrete surface within a time period and to a depth to facilitate removal of this paste after the concrete element is otherwise cured (a method of producing exposed aggregate nish). Return a projection of like cross-section which is 90 degrees to or splayed from main face or plane of view. Reveal (1) groove in a panel face generally used to create a desired architectural effect; (2) the projection of the coarse aggregate from the matrix after exposure. Rib (1) continuous vertical projection on a wall panel projecting a minimum of 6 inches from the panel face; (2) local thickening providing stiffness in concrete panels. Rustication a groove in a panel face for architectural appearance; also reveal. Sealers or protective coatings materials used to coast precast concrete units for the purpose of improving resistance to water penetration or for improving weathering qualities. Section cut away view through a general plan or elevation view to explain details. Segregation the tendency for the coarse particles to separate from the ner particles in handling; in concrete, the coarse aggregate and drier material remains behind and the mortar and wetter material ows ahead; this also occurs in a vertical direction when wet concrete is overbibrated or dropped vertically into the forms, the mortar and wetter material rising to the top; in aggregate, the coarse particles roll to the outside edges of the stockpile. Selfstressing forms equipment which in addition to serving as forms for concrete also accommodates the pre-tensioned strands (or wires) and sustains the total prestressing force by suitable end bulkheads and sufcient cross-sectional strength. Set-up the process of preparing molds or forms for casting, including locating materials (reinforcement and hardware) prior to the actual placing of concrete. Sand- that portion of an aggregate passing the No. 4 (4.76 mm) sieve and predominantly retained on the No. 200 (74 micron) sieve. Sandblast a system a abrading a surface such as concrete by a stream of sand, or other abrasive, ejected from a nozzle at high speed, by water and/ or compressed air. Sandwich wall panel panel consisting of two layers (wythes) of concrete fully or partly separated by a layer of insulation; in employing this detail, metal shear connectors are usually required to tie the two layers of concrete together. Sealants a group of materials used to seal joints between precast concrete units and between such units and adjacent materials.
Slab precast or prestressed oor or roof members. Spandrel that part of a wall between the head of a window and the sill of the window above it. (An upturned spandrel continues above the roof or oor line.) Spandrel beam beam in a building frame which extends between exterior columns at a oor level. Specications the type or printed directions issued by architects to establish general conditions. Standards and detailed instructions which are used with the contract drawings; contracted term, specs. Stone anchor an anchor commonly used to fasten cut stone units; such anchors are seldom suitable for use in precast concrete attachment. Stress intensity of force per unit area.
Tolerance specied permissible variation from stated requirements such as dimensions, strength, and air-entrainment. Topping concrete cast on erected prestressed units to achieve a level oor or to aid the units in uniformly carrying loads.
V
Vibration - energetic agitation of concrete to assist in its consolidation, produced by mechanical oscillating devices at moderately high frequencies; external vibration employs a device attached to the forms and is particularly applicable to the manufacture of precast items; internal vibration employs an element which can be inserted into the concrete, and is more generally used for castin-place construction.
W
Stripping the process of removing a precast concrete element from the form in which it was cast. Strong back a steel or wooden plate which is attached to a panel for the purpose of adding stiffness during handling, shipping, and/or erection. Structural a unit which carries live load or another units weight. Submitted presented to the architect/engineer for review. Systems building essentially the orderly combination of parts into an entity such as subsystems or the entire building; systems building makes full use of industrialized production, transportation, and assembly. Wall panel a component of a prefabricated wall which derives its strength and dimensional stability from a precast concrete element; the component includes any nonconcrete items incorporated in the element at the time of manufacture. Warping the bowing of a precast unit in two planes. Weep hole a hole provided for drainage through precast panel joints Weld to join metals by applying heat with a ller metal which has a high melting point. Welded wire fabric a reinforcing material composed of cold drawn steel wires fabricated into a sheet consisting of longitudinal and transverse wires arranged at right angles and welded together at all points of intersection. Weld plate a plate with attached anchors cast into concrete for the purpose of making a welded connection. Workability the ease with which a given set of materials can be mixed into concrete and subsequently handled, transported, placed, and nished with a minimum loss of homogeneity.
T
Temperature reinforcement reinforcement distributed throughout the concrete to minimize cracks due to temperature changes and concrete shrinkage. Tie a closed loop of small size reinforcing bars that encircle longitudinal bars in columns and beams. (see stirrup)
The Shockey Precast Group PO Box 2530 Winchester, VA 22604 540.723.4190 www.shockeyprecast.com

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TOTAL PRECAST SYSTEMS DESIGN GUIDE

Total Precast Systems Design Guide

3 19 55 69 95 101 111 123

The Building Envelope

DesignConsiderations Considerations Design

Components & Connections

Recent Case Studies

TPS Guide Specication

Eric Taylor Photography.

Features and Benets

Below: Typical example of how Total Precast System creates openness.

FLEXIBILITY OF SPACE PLANNING

THE SHOCKEY PRECAST GROUP , WINCHESTER, VA WWW.SHOCKEYPRECAST.COM

THE SHOCKEY PRECAST GROUP , WINCHESTER, VA WWW.SHOCKEYPRECAST.COM

Frederick County Public Safety Building - Interior Space Planning Layout

THE SHOCKEY PRECAST GROUP , WINCHESTER, VA WWW.SHOCKEYPRECAST.COM

THE SHOCKEY PRECAST GROUP , WINCHESTER, VA WWW.SHOCKEYPRECAST.COM

Frederick County Public Safety Building - Interior Space Planning Layout

THE SHOCKEY PRECAST GROUP , WINCHESTER, VA WWW.SHOCKEYPRECAST.COM

Erection of Stoneleigh at Westelds ofce building.

THE SHOCKEY PRECAST GROUP , WINCHESTER, VA WWW.SHOCKEYPRECAST.COM

CONSTRUCTION COSTS COMPARATIVE ANALYSIS FREDERICK COUNTY PUBLIC SAFTEY BUILDING

THE SHOCKEY PRECAST GROUP , WINCHESTER, VA WWW.SHOCKEYPRECAST.COM

THE SHOCKEY PRECAST GROUP , WINCHESTER, VA WWW.SHOCKEYPRECAST.COM

THE SHOCKEY STORY

Shockey Precast Group casting yard.

Fairfax Judicial Center Parking Structure, Fairfax, VA

STRUCTURAL PRECAST SYSTEMS Parking Structures

Shady Grove Metro Station, Rockville, MD

Calvert St. Parking Structure, Annapolis, MD

Largo Metro Station, Rockville, MD

THE SHOCKEY PRECAST GROUP , WINCHESTER, VA WWW.SHOCKEYPRECAST.COM

Eric Taylor Photography.

Shady Grove Metro Station Parking Structure, Rockville, Maryland

ARCHITECTURAL PRECAST SYSTEMS

First Mariner Bank Tower at Canton Crossing, Maryland

John Paul Jones Arena, University of Virginia, Charlottesville

THE SHOCKEY PRECAST GROUP , WINCHESTER, VA WWW.SHOCKEYPRECAST.COM

TOTAL PRECAST SYSTEMS

SHOCKEY TPS HISTORY

Tracor ofce building

Echostar Communications uplink facility

Fredrick County Public Safety Building, Winchester, VA

Fredrick County Public Safety Building erection

Highmark Data Center, Harrisburg, PA

Highmark Data Center erection

Stoneleigh at Westelds, Chantilly, VA

THE SHOCKEY PRECAST GROUP , WINCHESTER, VA WWW.SHOCKEYPRECAST.COM

THE SHOCKEY PRECAST GROUP , WINCHESTER, VA WWW.SHOCKEYPRECAST.COM

Eric Taylor Photography, 2006

THE BUILDING ENVELOPE

Stoneleigh at Westelds Ofce Building One erection, 2006

Typical Total Precast Systems Applications:

Stoneleigh at Westelds project wall panel

THE SHOCKEY PRECAST GROUP , WINCHESTER, VA WWW.SHOCKEYPRECAST.COM

Eric Taylor Photography.

Government Public Safety Building - Elevation on Grid A, South Side

THE BUILDING ENVELOPE

THE SHOCKEY PRECAST GROUP , WINCHESTER, VA WWW.SHOCKEYPRECAST.COM

MISSION CRITICAL DATA CENTER

THE SHOCKEY PRECAST GROUP , WINCHESTER, VA WWW.SHOCKEYPRECAST.COM

THE BUILDING ENVELOPE

HIGHMARK DATA CENTER