ASV
Ladysmith, Virginia
Thin Brick Faced Precast
American Stone Virginia, LLC
4/9/2020
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What is Thin Brick Faced
Architectural Precast
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Thin brick faced precast is conventional Architectural Precast
Concrete (APC), section 3450 with portions, or sometimes
all, of the exposed to view face covered by a thin section,
kiln fired clay masonry unit.
The result is a panel with natural masonry appearance usually
accented by areas of smooth or textured architectural precast
but with the benefits of APC.
Section 3450 (PCI MNL 117) APC producers are accustomed
to the requirements of high end architectural finishes and
uniquely qualified to produce this product
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Design Flexibility, Considerations and Benefits
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Incorporation of various sections and shapes into design
Unlimited color selection and various textures; acid
etched, sandblasted, exposed aggregate
Accommodate seismic and blast load design criteria
Stacked or gravity loads to structure (Column and
Spandrel) impact on structure and connections
Panel size considerations and Limitations
Insulated panels possible
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Project and Onsite Considerations
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Use of APC shortens the onsite project schedule
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Better jobsite efficiency through elimination of
conventional masonry scaffolding and a reduction of
onsite activity and trades
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Less weather sensitive
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Get under roof sooner, allowing follow up trades
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What is the access for erection equipment and crane
reaches
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Green Building Considerations
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Use of APC eliminates the jobsite waste generated by
conventional masonry
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Most APC producers will be located and obtain their raw
materials (except the thin brick itself) within 500 miles of the
jobsite
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Energy cost of manufacturing thin brick is only 18% of the
cost of full size brick
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Applications
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Thin brick/APC can be utilized on any structure where a
masonry appearance is desired.
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Panel sizes can be maximized to improve erection efficiency
or elements can be reduced in size to accommodate a
different architectural appearance.
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The use of APC finish as an integral trim feature adds detail
and variety with out added cost.
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Project Examples
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Office and Headquarters facilities for civilian
and military users
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Administration and warehouse facilities
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Parking Structures
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Fort Lee SCOE office and headquarters building in thin
brick with acid washed precast in a spandrel and column
design
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SCOE-1
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APC base panel, TFB columns and spandrels
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SCOE-2
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APC spandrels in medium acid wash finish
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SCOE-3
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Interface of APC and TFB panels
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St Agnes Parking Garage-Baltimore Md
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Interesting use of TBP/APC to create the effect of row houses in an urban
neighborhood
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St Agnes Parking Garage
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Two brick colors with acid washed APC
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Upper Rock Parking Garage
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Conventional garage with APC spandrels and TBP stair towers
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Upper Rock Parking Garage-2
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Projecting APC window surrounds adds depth
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Ft Lee Central Campus
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Office, Administrative and warehouse functions
Masonry and two APC finishes
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Ft Lee Central Campus
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Stacked wall panels with minimal blast loading
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Design Considerations
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Overall building use and design complexity
 Thin brick adds cost compared to a conventionally
finished APC panel
 Use of thin brick requires careful attention to coursing in
detailing, production and erection
 On site accommodation (“fudging”) that is available with
conventional hand set masonry is not available in APC
 Fabrication and erection tolerances must be recognized
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Alignment Issues
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Reveal details, brick coursing and panels themselves all need to align
within tolerances
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Which basic APC design will be used:
Stacked or spandrel-column system
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Building Appearance and function
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Higher end office or more one that is more functional in
nature
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Stacked system
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What is the building story height and blast load requirements
Requires lighter structure since no gravity loads
Less design flexibility
Produces the more typical appearance and shape. (Big
box/warehouse)
Generally less expensive to erect and produce since more
repetitive and jobsite erection access is better.
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Basic Structure
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Three story Building
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Spandrel and column design (non –stacked)
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More flexible, allows for more shape and complexity
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Greater story heights since panels aren't stacking
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Usually includes smaller, lighter panels
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More panels to erect
More panels per trailer= fewer loads and fewer trailers required onsite at a given
time
Can use smaller crane (cost partially offsets more panels)
Site access requirements usually less demanding than with larger panel stacked
system
Gravity loads transferred to columns or slabs, not to footings
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Especially if blast load requirement
Precast connection design more demanding and expensive
Better able to accommodate high performance blast (no progressive failure)
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Multi Stories, punched windows
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Connections for Gravity and Blast
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Load bearing haunch connection and blast load tie back in Spandrel and
Column format
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Panel Sizing
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Generally fewer panels= lower cost
What is the jobsite access and crane availability
Transportation concerns; size weight, costs
Plant capacity to produce panel size and weights
Typical panels not to exceed 12’ wide and 35’ tall x 8”
thick (42,000#)
Wider panels possible but production and shipping costs
increase
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Large Panels demand better jobsite access and
coordination
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The Manufacturing Process
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Color and Finish Selection
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Match existing or new sample
Color and finish
Mock up or sample panel requirement options
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Smaller 1’x1’ initial sample
Followed by larger sample panel 3’x 3’ to site
Onsite mock up with other trades
Full size production review onsite or at plant
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Shop Drawings
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Status of Contract Drawings
Plans and Specs
Design-Build
 APC producer in lead
 Basic building frame and design from designers
 Coordination with design team
 Critical building dimensions must be agreed upon
 Coordination with other trades critical (structure,
windows)
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Molds
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Casting Area allows custom molds to accommodate any project
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Brick Formliner
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In house production of rubber formliners means control of
quality, more customization and less chance of delays
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Brick Preparation
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Brick being coated with bond breaking wax to allow for later washing
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Mold Construction
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Molds constructed on polyester coated wood forms with multiple reveals
and blockouts
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Brick Placement in Molds
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Pre pour preparation
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All mold joint prepped and caulked to prevent leakage from form
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Quality Control
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Panel being Pre pour inspected for conformance to shop drawings
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Ready for Production
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Brick installed, joints caulked, form oiled , sizes checked
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Concrete Batching
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In plant batching with architectural grade equipment
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Casting
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First layer of concrete facing placed and consolidated, reinforcing steel placed and
hardware located
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Embed Placement
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Finishing
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Panels transported to acid washing or sandblasted station
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Yard Finishing-Patching
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Skilled finishers make all the difference in an architectural product
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Finished Panels in Storage
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Sandblasted and acid washed panel
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Special Feature Panels
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Specialized trailers for transport of large panels
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Trailers loaded for transport
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Adequate number of trailers staged for delivery
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Ready for Installation
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Erection in Progress
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Erected
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