Staying Ahead of the Industry: PCI Exceptional Precast Practices Program

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Mid-States Concrete Industries is one of only seven producers in the nation to be part of the PCI Exceptional Precast Practices Program in 2017-2018. The program focuses on continuous improvement, strives to improve efficiency, and provide client value while placing safety and environmental responsibility at the forefront of business.

Producers that participate in the EPP Program may be described as follows:

  • The firm is professionally managed and reliable

  • Uses the latest tools and techniques

  • Participates in the PCI QA program

  • It has established processed and predictable results

  • It is seeking continuous improvement

  • It strives to improve efficiency and provide client value

  • Takes safety seriously

  • Takes environmental responsibility seriously

~ Information courtesy of PCI.

Innovative Graphic Concrete

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In an effort to offer customers the latest innovations in precast, the Mid-States Concrete Industries team has spent the past several months studying and testing the use of graphic concrete.

Graphic concrete enables durable patterns and images to be produced on precast surfaces through the use of a membrane with a surface retarder. Concrete is cast on the membrane and when the retarder is washed away, the image is revealed. Mid-States has partnered with Graphic Concrete LTD to learn more about this exciting new tool, so we can offer it to you.

Graphic Concrete has been used in more than 600 projects in 25 countries around the world by numerous architectural offices and concrete element factories. Mid-States has used graphic concrete to cast our own logo into the new water reclamation center at our plant. We have also experimented with how we could incorporate it into some of the projects we are currently involved with.

If you are interested in more information about graphic concrete, please contact sales@msprecast.com.

St. Augustine Preparatory Academy

Our mission is to build meaningful buildings in which to live, work and play. These are not just words to us, but an opportunity to impact people in an amazing way. We are extremely grateful to have been part of building St. Augustine Preparatory Academy in Milwaukee.

Mid-States was excited to partner on this project, and provided 96 Wall Panels, five precast columns, and 1,600 square feet of Hollowcore for the school’s natatorium and gymnasium.

St. Augustine Preparatory Academy is a K4-12 non-denominational Christian school on Milwaukee’s south side. The school is a student-centered environment where young learners take ownership of their education not only in academics, but also physical health, creativity, and faith. The school’s vision statement is: “St. Augustine Preparatory Academy develops students to be tomorrow’s leaders. They will be known by their strength of character, courage, intellect, impactful contributions and their faith.”

The Ramirez Family Foundation supplied $43 million of the $53 million cost and is subsidizing students’ tuition at the private school. The 192,454 square foot school was developed around a 5.6-acre parcel. The athletics facilities are open to the community and include a 1,000 seat gymnasium, a turf athletic field and running track on the 12-acre property, as well as a competition natatorium housing a competition-sized pool. St. Augustine is also home to an in-school health clinic.

The school’s curriculum is based on curriculums from successful schools across the country and sets high expectations for every student. It aims to be one of the highest performing urban schools in the country. St. Augustine Preparatory Academy just completed its first school year in 2017-18.

Project Partners:
   •  Owner: Achieving Educational Excellence Inc.
   •  GC: VJS Construction Services
   •  Architect: Korb & Associates Inc.
   •  EOR: GRAEF

Proud Partner of the Ronald McDonald House Madison Addition

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Our mission is to build meaningful buildings in which to live, work and play. These are not just words to us, but an opportunity to impact people in an amazing way. We are extremely humbled and grateful to be able to work on the addition of Ronald McDonald House in Madison.

Without the services of Ronald McDonald House, families would be forced to choose between being with their child and incurring the financial burden and emotional toll of being away from home or not being close to their child. The Ronald McDonald House helps families stay together while away from home during some of the hardest times they will ever face. This addition will allow Ronald McDonald House to help even more families.

As Madison’s medical care has become increasingly sought-after, Ronald McDonald House Madison has seen an increase in need for its services. Last year, there were 461 night stays Ronald McDonald House Madison was not able to accommodate. Founded in 1993, Ronald McDonald House Madison has housed more than 26,000 families since it opened.

The Ronald McDonald House expansion will increase square footage from 17,600 to 32,000 and will provide an additional 13 guest rooms. The project will also include landscaped green space; expanded indoor and outdoor play areas; remodeled common areas and an improved kitchen and dining room; added underground and surface parking; more convenient guest access and improved entry security system; and a quiet room where guests and visitors can gather privately.

We are so proud to be part of this project. Precast on the addition includes nearly 9,000 square feet of hollowcore and solid slabs, 10 columns and 18 beams. The precast will be used for the underground parking area and to create the podium for the addition.

The Building Envelope

Due to its density, concrete has the capacity to absorb and store large quantities of heat, contributing to a high-performance building envelope. Its thermal mass allows concrete to react very slowly to changes in outside temperature to reduce peak heating and cooling loads and delay the time at which these loads occur. The resulting savings can be significant—up to 25% of heating and cooling costs.

Thermal mass and energy savings
ASHRAE Standard 90.1
acknowledges the thermal mass benefits of concrete walls in specifying lower minimum insulation R-value and higher maximum wall U-factors for mass (concrete) wall construction.

Research conducted by Oak Ridge National Laboratory compared the dynamic thermal performance of insulated concrete walls with that of a traditional wood frame. Research shows that insulated concrete sandwich walls constructed with composite connector technology utilize the thermal mass effect of concrete to create an “equivalent wall performance R-value” several times greater than a traditional material R-value calculation.

Energy-saving benefits of thermal mass are most pronounced when the outside temperature fluctuates above and below the balance temperature of the building, causing a reversal of heat flow within the wall. The balance point is generally between 50 and 70°F.

These ideal conditions for thermal mass exist on a daily basis at all locations in the United States.

Another factor affecting the behavior of thermal mass is internal heat gain. This includes heat generated inside the building by lights, equipment, appliances, and people; and heat from the sun entering through windows. Generally, during the heating season, benefits of thermal mass increase with the availability of internal heat gains. During the cooling season, thermal mass exposed to the building's occupied spaces will absorb internal gains, shifting peak cooling periods. Concrete exposed to the interior, not covered by insulation and gypsum wallboard, works best to absorb internal gains, saving cooling energy.

Thermal mass also works well when daily temperatures have large variations between the daytime high and nighttime low and when outdoor air can be used for nighttime ventilation.  Designs employing thermal mass for energy conservation should be given a high priority.

Color
Color (albedo)
of precast concrete panels can be used to improve the energy-conserving features of the walls. Panels with high albedo (generally lighter in color) can help reduce the urban heat-island effect. Albedo is the ratio of the amount of solar radiation reflected from a material surface to the amount that shines on the surface.

Generally, materials that appear to be light colored have high albedo and those that appear dark colored have low albedo. On exterior surfaces, high albedo decreases solar heat gain; low albedo increases solar heat gain. A low albedo north wall and high albedo east and west walls and roof form the most energy-conserving arrangement in a northern hemisphere climate that uses both heating and cooling. High albedo surfaces are especially important where cooling dominates the energy requirements. It should be noted, however, that the color of the exterior walls has less effect on energy consumption when the walls have high R-values and thermal mass.

Heat-island effect
Light-colored exterior surfaces also help reduce urban heat-islands. Urban areas are up to 7°F warmer than the surrounding areas. This difference is attributed to more buildings and pavements that have taken the place of vegetation. Where buildings and paved surfaces are required, using materials with higher albedos will reduce the heat-island effect, save energy by reducing the demand for air conditioning, and improve air quality.

Air infiltration
Air infiltration has significant effects on the amount of energy required to heat and cool a building. Large precast concrete panels have minimal joints, reducing uncontrolled air infiltration.

~ Information provided courtesy of PCI.