CarbonCast® Non-Structural Insulated Wall Panels

CarbonCast High Performance Insulated Wall Panels are self-supporting units featuring edge-to-edge continuous insulation (ci) as defined by ASHRAE 90.1. CarbonCast panels provide steady-state R-values of up to R-30 and higher per design. Used in loadbearing and non-loadbearing conditions, the panels are intended for vertical and also horizontal placement. Panel thicknesses can vary from 7" to 12".

Learn More Nonstructural Panels Below

Learn about our structural insulated wall panels.

Overview

• Continuous insulation to meet ASHRAE requirements
• Up to 40% lighter; enables reduced superstructure and foundation
• Reduced project carbon footprint
• Aesthetic flexibility
• Produced under license from AltusGroup, Inc.

Applications

The panels can be stacked for low- and mid-rise applications.

Cost

$$-$$$

Technical Overview

Connections

Connections are typically welded or bolted

Concrete

Mix:

• Exterior wythe: architectural mix
• Interior wythe: EcoMix (up to 50% recycled content per design requirements)

Water-cement ratio: less than or equal to .38

Strength: 5-7,000 psi

Color: per design

Fire Performance

ASTM E 119

Up to 3 hours

Reinforcing

Primary reinforcement – 3/8” prestressing strand and mild steel rebar per design

Transverse reinforcement – welded wire fabric or C-GRID® carbon fiber mesh

Shear reinforcement – C-GRID carbon fiber mesh

Specifications

Certification . . . . . . . . . . . . . . . . . PCI Certification

Design. . . . . . . . . . . . . . . . . . . . . . ACI 318

Prestress strand . . . . . . . . . . . . . .  ASTM A 416

Reinforcing steel. . . . . . . . . . . . . . ASTM A 615

Welded wire fabric . . . . . . . . . . . . ASTM A 185

Structural steel . . . . . . . . . . . . . . .  ASTM A 36

Aggregate. . . . . . . . . . . . . . . . . . .  ASTM C 33

Cement. . . . . . . . . . . . . . . . . . . . .  ASTM C 150 Materials

Dimensional Tolerances:

Horizontal alignment:

Position of Weld Plates: ±1 in.

Options

Varying thicknesses – interior wythes are typically 2" thick; exterior wythes are typically 3” thick. The exterior wythe can be thickened to accommodate architectural details.

R-values – insulation thickness can be increased to meet higher R-value demands.

Insulation types – typically expanded polystyrene (EPS, white in color); extruded polystyrene (XPS, blue or pink in color) also available.

Shapes – an assortment of architectural elements such as cornices, bullnoses and reveals can be cast into the concrete carefully and cost-efficiently.

Embedded finishes and veneers – stone, tile and thin brick can also be used as well as simulated limestone or granite.

Panel orientation – typical orientation will be horizontal; vertical orientation is possible.

Prefinished interior wythe – a steel-trowel treatment during manufacturing imparts a smooth, durable, surface ready for paint or wallcovering and ideal for applications like dormitories and apartments.

Grouted connection tubes – prefabricated plastic forms, fit into foundations and panels to facilitate connection (uat.highconcreteaccessories.com)

LEED

LEED®

Potential precast point contributions to LEED 2009 certification:

*Provide Specific Title: High Concrete Group encourages applications for CarbonCast carbon fiber reinforcement because it reduces cold spots and embodied energy relative to other precast concrete systems.