The two-story, 108,000 ft2 Willow Creek Elementary School was built in response to increased enrollments at the elementary school level. The school opened for the 2009-2010 academic year and features 44 classrooms, a cafeteria, gymnasium, library, computer labs, art, and music classrooms for an estimated 700 students.

The $22.1 million school was designed by AEM Architects, Inc., which also designed the nearby Tilden Elementary Center in Hamburg, PA with CarbonCast High-Performance Insulated Wall Panels. The Tilden school was completed in 2007.

Willow Creek was built in proximity to other Fleetwood facilities and takes the place of an older block and brick structure. According to AEM project architect Justin H. Istenes, the insulated wall panels were chosen for the school because “precast is built to last. The owners toured High’s Denver plant and the Tilden school while it was under construction, and were satisfied they were getting better value with precast insulated wall panels.”

An outstanding thermal performance was achieved at Hamburg Elementary school (Tilden) with CarbonCast walls. Amid skyrocketing energy costs and heightened public awareness of green construction practices, more building owners are seeking environmentally friendly solutions without incurring higher costs.

Tilden Elementary Center in Hamburg, PA, is no exception. The school for kindergarten through fifth-grade students will save on heating and cooling costs with innovative precast high performance insulated wall panels engineered, manufactured, and erected by High Concrete Group.

High Concrete’s 10”-thick precast exterior walls on the 110,000-square foot project delivers R-15 performance. They use three inches of continuous XPS insulation (“ci” as defined in ASHRAE Building Energy Code 90.1-2007) sandwiched between a 4” interior wythe and a 3” exterior wythe. C-GRID carbon fiber shear grid connects the two wythes. With relatively low thermal conductivity, the carbon fiber prevents thermal transfer, virtually eliminating hot and cold spots on the interior wall preserving comfort for students.

High’s precast walls helped keep the project on schedule and under budget, both of which are critical for a public school. The project was completed in June 2008—in plenty of time for teachers to welcome students for the first day of school.

Opened in fall 2013, Mercy Health - West Hospital brings a new level of healthcare to Cincinnati's west side. The 625,000sf project features 250 beds, comprehensive cardiac care, an oncology treatment center, a maternity and birthing center, and Ohio's largest green roof. The medical facility eliminates the need for the local residents to travel outside of the area for full-service medical care.

The medical facility features state-of-the-art care combined with amenities that focus on the patient and their families to create a comfortable and healing atmosphere. This approach to health care architecture, balancing beauty, culture and function set a new standard for hospital design. Connections between architecture, natural light, and landscape promote healing.

Located on a 60-acre wooded site, the hospital's large diagnostic and treatment base is designed to co-locate surgery, imaging, the emergency department, and cardiovascular ICU. Two-bed towers sit on this platform, which features a living roof covered with native plants — providing an ever-changing view from the patient rooms above.

The unique, 107,000sf green roof covers 2.5 acres and has more than 65,000 plants. Patients and visitors can enjoy views of the roof from the patient towers, as well as an observation area. The roof helps maintain cooler building temperatures during summer months, while capturing and holding 75% of rainwater, thus lessening the amount of stormwater run-off.

A design-build approach that reused steel forms from an award-winning project resulted in the 315-space Lehigh University Alumni Parking Garage in four to six months less time than typical construction. The form design was recognized with a PCI Design Award in 2002 and again in 2007 when it was repurposed for this project.

The five-level, 104,000 square foot garage for university faculty features 10- by 30-foot precast concrete elements that incorporate slender precast concrete columns and spandrel beams. The structural design eliminated tall, heavy spandrels that are traditionally associated with parking structures, replacing them with an open, lightweight concrete latticework that provides both exciting form and efficient function. The panels' slender columns correspond individually to the 7-foot 6-inch span of the 15-foot-wide structural double tee stems. In addition to bringing in light and providing an open, airy feel, the exterior lattice system blocks headlight beams from reaching into the neighborhood.

In 2012, the Christ Hospital Network in Cincinnati, Ohio, decided to add an orthopedic center of excellence to its already nationally renowned healthcare facility. The owners worked with an architect to design the seven-story, 381,000 ft2 LEED Silver-certified Joint & Spine Center, which linked it directly to the hospital’s existing surgical and imaging areas.

As part of the broader master plan, the client and architect agreed that the design for the Joint & Spine Center needed to reflect the historical redbrick vernacular of the other campus buildings. It also had to meet strict budget restrictions, deliver a watertight building envelope, and meet the high-performance goals set for the new building. All of these requirements would be met with a precast concrete design.

2019 PCI Award Winner

In a recent and unconventional interpretation of this concept, the New Brunswick Development Corporation (Devco) has completed Gateway Transit Village, a mixed-use, transit-oriented design consisting of a 24-story building and a new pedestrian walkway directly adjacent to a NJ Transit/Amtrak station. Located in the heart of downtown New Brunswick across from the Rutgers University campus, the new $150 million, 632,000-square-foot structure is the tallest parking garage and building in the city. A precast parking structure from High Concrete Group LLC forms its core.

Built as part of an ongoing revitalization effort, the new complex is intended to help bring renewed life to a site that is vital to the city, but that has been under-utilized for many years. With views of the Raritan River, the apartments and condos in the tower are targeted to attract people who already live and work in New Brunswick. Twenty percent of the units are set aside for moderate- and low-income owners.

The project is unconventional in several ways. "Gateway is the most urbanly dense transit village in New Jersey," notes David J. Stuart, project manager for New York City-based Meltzer Mandl Architects. "Everything that’s normally incorporated into a transit village has been combined into a single structure."

"Also, precast concrete parking garages are not typically designed to support taller and more complex structures above them; they are usually stand-alone buildings. To place a 14-story building on top of a garage is daring structural engineering," says Stuart.

Gateway Transit Village consists of a 10-story precast parking garage with 697 parking spaces, topped by a 14-story steel-frame and hollowcore residential tower containing 150 apartments and 42 condos. The structure is wrapped by 120,000 square feet of offices and a series of street-level commercial spaces for tenants, including the Barnes & Noble College Bookstore for Rutgers and offices for the New Brunswick Parking Authority and the Rutgers University Press.

Stuart notes that Gateway Transit Village doesn’t relate to its context as much as redefine it. "A typical approach would be to hide the parking garage, and disguise the precast," says Stuart. "At first we considered thin brick, to match other parts of the structure. But we decided that we wanted an exposed concrete aesthetic for the podium, to let concrete be concrete, and to show its inherent nature. Precast concrete can be quite elegant, minimalist. It was economical, fast, and gave us pleasing aesthetics."

The majority of the garage was cast in a standard High Concrete Group buff architectural mix and finished with a light sandblast. Simple reveals set up a rectangular pattern that brings scale to the horizontal spandrels and complements the openings between them on the way up. Spandrels at the top are finished with a small cornice.

The parking garage required 24-foot and 36-foot spacing between the support walls to optimize the parking spaces and 12’-wide precast double tees. The residential tower called for a different supporting grid, which had to have its column lines aligned with the garage support walls via 10-inch-thick hollowcore plank spanning up to 36 feet.

"This is a good use of precast," says J. Benji Alper, PE of engineering firm Severud Associates’ New York office. "While the precast garage is only 10 stories, the overall structure still stands at 24 stories tall, requiring the precast walls to resist the forces for the full lateral and gravity loads of the 24-story building." He discusses the approach in the Structure Magazine article,"Integration of Diverse Structural Systems and Design Delegation in a Mixed Use Space."

Alper notes that communication was critical in the project. "Immediately after the contract award, weekly meetings were conducted with the entire design team which included members from the precast manufacturer’s engineers, the structural engineer, the architect, the parking consultant, the owner, and the general contractor. Other trades, including the steel fabricator, the steel detailer, and the erector, also would often attend. The meetings were a key part of an iterative design process between Severud and High Concrete Group."

As the use of a structure changes over time, the facilities themselves must adapt. Sometimes, this means fully demolishing an existing structure to accommodate the evolving needs of its tenants. This was the case at a regional medical center, where plans were made to replace a parking garage to increase capacity and functionality. The project would feature six levels and a total of 851 parking spaces along with the construction of medical offices within the new structure. The medical center also wanted to design their new garage with flat levels so patients with mobility issues could easily access the main buildings without having to navigate ramps or stairs. It was crucial to avoid disruption of hospital access for employees and patients during construction. The bulk of this project also happened to take place during the peak of a pandemic, meaning that the hospital had higher traffic and that it was even more important to minimize disruption of the medical center’s activity.

2023 PCI Design Award Winner

This collegiate pedestrian bridge harmonizes with a collegiate campus that has been around for years. The environment of a college tends to develop around them, causing a need to adapt. Taking something that was, “a necessity and turning it into an asset” was an added benefit to the Architect. Ultimately plastic and versatile, precast concrete helps designers realize their vision even when it’s not the hero in the visual. In this project, harmony, and consistency with the campus aesthetic was a high priority to both the University and the designers. To achieve this goal, the design included a fieldstone veneer to the exterior of the precast bridge following erection except for the architectural panels over the road. The panels over the existing road had the fieldstone applied by the precast manufacturer to the panel prior to being transported to the location. This helps cut down road closure time and boost efficiency.

2020 PCI Award Winner

Once bustling with retail business and pedestrian traffic, the City of Lancaster, PA is working toward rebuilding a vital and vibrant downtown. Designed with an intention to stimulate the Lancaster economy with much-needed commuter and transient parking and 15,000 square feet of retail space on two floors, the 185,000-square-foot Queen Street Station Parking Garage complements the city’s historic streetscapes and creates a pedestrian-friendly aesthetic.

Following Hurricane Sandy in 2012, many structures owned by Nassau County in New York state were evaluated for structural damage, including the police precincts. Prior to the storm, several of these buildings had already been in need of renovations to accommodate a growing police force and resolve problems of aging infrastructure, and the storm accelerated this need, says Gilbert Balog of LiRo Architects + Planners.

In the 8th District, Nassau County wanted to replace the 1950s-era frame and brick precinct buildings with structures that communicated civic pride and could withstand the onslaughts of future major events. “Resiliency was a major factor in the selection of precast concrete construction,” says Dianne Pohlsander, design architect for LiRo. “In fact, everything came together with precast concrete: resiliency, fabrication that wasn't weather dependent, constructability, and the desired aesthetics.”

Precast concrete also helped address unique logistical challenges on this project. Construction was constrained by long and narrow site, and, because the new precinct house was constructed at one end while the old building stayed open for operations at the other, the team was under pressure to complete the project quickly with minimal site disruption. “Precast concrete gave us that quick erection time that we needed,” Pohlsander says.

2019 PCI Award Winner

The TQL Ivy Pointe Office building is predominately thin brick-clad with light sandblasted buff-colored precast details framing the spandrels. The precast provides a face-sealed curtainwall that provides effective moisture control that typical rain screen construction cannot.  The thin brick is finished with a rake joint.  Additional precast details include a 2-1/2’ projection below the parapet to lend a dramatic shadowline.  The parapets themselves are at a height of 42” over the roofline to allow maintenance and other personnel to work on the roof without tying off.

The design made repeated use of a few stacked panel designs, allowing maximum economy.  L-shaped thin bricks wrapped around window returns as would a full depth brick course.   Formliner created a stone look formliner to the columns at the main entrance to add to the feeling of solidity.  Reveals add drama and break up the mass to create a human scale.

When planning to construct a new performing arts building, Villanova University weighed the many options for construction materials. As part of the University’s project to transform a previously underutilized parking lot into a multi-use area, including student housing, retail, and dining, the performing arts center acted as the crown jewel of the development. Through this development project, the University intended to provide the local metropolitan community an opportunity to experience new forms of art and culture, while also using the facility as a hands-on learning experience for theatre students. To achieve this vision, the structure needed to house a full-size theater, along with studios and classrooms, and provide adequate acoustic isolation between the spaces. Villanova is known for its Gothic-style architecture across campus, so the new design also had to complement the aged architectural style of its surroundings. Creating precast panels with plant-installed stone could meet the aesthetic and functional needs of the university with lower costs and construction time than a traditional stone façade.

2023 PCI Design Honorable Mention