Architectural Precast Concrete

Yes, but only if shapes are repetitive. It costs considerably more to create an original mold (or form) for complex shapes/profiles. However, if 20 to 30 castings are made from a single mold, the cost is amortized over all of the castings, reducing the premium to a nominal amount per casting.

There are numerous ways in which precast color uniformity can be enhanced.

The goal is to have color uniformity, but any concrete, depending on color and mix can vary. The finish of concrete also can add in an additional variant. High Concrete Group follows the PCI regulations on the color range.

All non-earth tone colors (blue, green, red, yellow) are the most difficult to keep a closer color variation than earth tones (gray, tan, white).

There are numerous ways in which precast color uniformity can be enhanced.

Use a retarded finish. This exposes the coarse aggregate, permitting the coarse aggregate's uniform natural color to "carry" the panel's color. In doing so, be certain to use a color compatible matrix (sand/cement/pigment), in order to mask any uneven coarse aggregate dispersion.

Use white cement instead of gray cement whenever possible. White cement's color control is excellent. Gray cement manufacturers do not attempt to control color. Thus, gray cement color can vary widely even within a single SUPPLIER, causing significant precast color variations.

Remove a sufficient amount of the as-cast concrete's surface. All concrete is blotchy when left as-cast. The surface "paste" or "skin" must be removed in order to reveal the true concrete color. For example, light acid etching is apt to result in a blotchy or shaded appearance because the acid does not remove all of the surface "paste" or "skin". Therefore, acid-etched finishes should be deep enough to reveal the tips of the coarse aggregate. Likewise, lightly sandblasted finishes should reveal some coarse aggregate, in order to appear reasonably uniform.

Avoid large planes of smooth, uninterrupted surfaces. If the eye has nothing to focus upon except large expanses of plain, smooth concrete surfaces, it will perceive minute panel to panel color differences. If instead, such large surfaces are interrupted by rusticated joint patterns, plane changes, and/or mix/finish changes, the eye will be drawn to these features making slight color variations, panel to panel, almost indistinguishable and unimportant.

Avoid using pigments in very small dosages. Pigment content, as a percentage of the total ingredients in a concrete batch, is very small. As that percentage diminishes, the likelihood of increased pigment content variation, batch to batch, goes up dramatically causing noticeable color variation.

Multiple mixes will increase cost. Consult your High representatives before finalizing your design, because some mix and/or finish combinations require more additional labor than others.

Small precast pieces usually cost much more per square foot than large pieces (pieces 100 sq. ft. or larger) because handling costs (i.e., stripping, finishing, yarding & loading, hoisting and connections) are similar for small and large pieces. The cost for handling small pieces is distributed over fewer square feet per piece than in large panels so that the handling cost per square foot for small panels is greater than for large panels. Where possible, combine small pieces with adjacent precast pieces.

The most important thing you can do is call 1.800.PRECAST to involve your HCG representative as early as possible in the development of your project's architectural precast application. Our sales representatives are trained to help designers maximize the value of their precast design. For example, how a precast exterior is panelized can affect cost significantly with little or no difference in appearance. Also, a designer can employ important features such as reveals, rustication joints, medallions, form liner patterns, etc. at very little additional cost, but only if such features are used repeatedly (avoiding costly, frequent form changes). It's important to know what design techniques to use and when to use them. Contact your High sales representative.

We are certain that you, as well as your client, expect your building's exterior to become the high quality realization of your design's intent. And the best assurance that your project will be a high quality result is to rely upon the industry's only truly independent certification program - PCI's plant certification program.

There are four (4) compelling reasons to choose architectural precast concrete for your building's exterior:

1. Architectural precast is the only cladding material that permits you, the designer, to custom design shape, color, texture, and pattern - only you control your building's unique, custom exterior look.

2. Architectural precast enables you to enclose your building's exterior in a small fraction of the time versus most all other cladding materials - this reduces construction cost dramatically and provides your client much earlier occupancy.

3. Proven low initial cost. Architectural precast concrete is used widely by office building developers nationwide. They tell us it is their cladding material of choice because it offers a high quality "look" at a very economical price.

4. Long term maintenance is almost negligible. All you need to do is re-caulk the precast joints after 15 to 20 years.

Certainly! We encourage you to do so. For a minimal additional cost (some additional reinforcing and minor additional connection cost) architectural precast concrete can become a terrific load-bearing element.