Thermal Efficiency Saves Money

Thermal Efficiency of CarbonCast®
The U.S. Department of Energy estimates that 42 percent of energy consumed in a building is ultimately lost through the building envelope, or the barrier between the building interior and outdoor environment.  A significant portion of any commercial envelope is the exterior wall.

The building envelope is critical in regulating internal building temperatures and determining how much energy is required to heat or cool a structure for occupant comfort.  Heat transfer through envelope components such as walls wastes energy.  Thermally efficient exterior wall systems aim to mitigate heat transfer and energy loss.  They are engineered to minimize the opportunities for heat to flow from the interior surface through the wall to the building’s exterior.

The role of wythe connectors
In insulated precast concrete wall panels, wythe connectors act as a mechanical connection between the inner and outer layers of concrete.  Because they form a connection through the insulation, there is an opportunity for thermal bridging to occur as well.  Traditional wythe connection options such as solid zones of concrete or metal connectors – while providing a reliable mechanical connection – permit heat transfer between the wall because of the materials’ inherent conductivity.

What is important is designing a performance specification on the overall wall system rather than just the connector alone.  A specification based on the overall wall system is one of the best ways of ensuring that the enclosure will meet the owner’s standards.

The role of insulation
Insulation helps to prevent the flow of heat across the exterior envelope.  The use of continuous insulation further stems the flow by eliminating the presence of building materials that could facilitate thermal transfer.

Continuous insulation is defined in ASHRAE 90.1 as “insulation that is continuous across all structural members without thermal bridges other than fasteners and service openings.  It is installed on the interior or exterior or is integral to any opaque surface of the building envelope.”

The thermal performance of edge-to-edge insulated precast sandwich wall panels with no or minimal thermal bridges and no solid zones maintains the R-values for continuous insulation as defined in ASHRAE 90.1, thereby lowering energy costs for the owner and occupant.

~ Courtesy of AltusGroup

Design Assist Impacts Project Delivery

In recent years, a trend toward early integration of the design/build process has developed into what is now called design assist.

In this process, the precast concrete producer is selected based on qualifications for executing the demands of the specific project, PCI Certification, and the capability for technical expertise to assist the design and construction team in the development of the project. A contract is then awarded and should, at a minimum, include compensation for the design assistance. Significant benefits can be achieved if the contract also includes the supply and installation of the final products.

Benefits of design assist include development of concrete mixtures and finishes during the development process rather than going through a sample approval process after bid and award. Requests for information are eliminated with the precast supplier as a participating member of the design team. Precast erection drawings are prepared as design development nears completion, leading to a much smoother shop drawing review process. The structural design of the precast panel connections are completed in collaboration with the Engineer of Record to assure coordination with the design of the supporting and bracing structural system. The construction schedule is coordinated with the precast production schedule to assure timely delivery and installation. Any activity that normally occurs after award in a typical bid/build arrangement would be coordinated much earlier when the total precast contract is executed shortly after the design and construction team is assembled.

Precasters can offer detailed expertise that allows for expedited development of the design with engineering innovations and scheduling improvements while enhancing aesthetics and controlling budgets from conceptual design to project completion. Each element can be made as cost-effective as possible, taking advantage of the inherent performance characteristics of precast concrete. The precaster will be able to contribute design and detailing suggestions to ensure that maximum efficiency is achieved at the lowest erected cost. The result should be a functionally efficient and aesthetically pleasing enclosure that meets or exceeds the expectations for the project. Finally, the precaster should be considered as a partner on the design team. This will impose a responsibility on the precaster to understand related construction materials that must interface with the precast concrete so details appropriate to all the materials can be developed.

- Information courtesy of PCI

CarbonCast High Performance Insulated Wall Panels

Precast wall systems that are lighter, better insulating and more sustainable

You can design and build with lighter, continuously insulated, truly sustainable, and more energy-efficient precast wall panels using CarbonCast technology.

CarbonCast Enclosure Systems use advanced technology to improve precast concrete by integrating ultra-strong, non-corrosive C-GRID into wall panels during fabrication. By taking the place of steel reinforcement, C-GRID provides a multitude of benefits that makes factory-made precast concrete an even more intelligent choice for building envelopes.

Depending on design, CarbonCast panels are priced competitively with other curtainwall systems, such as brick-veneered, masonry, stud walls, or concrete. And after factoring in reductions to superstructure requirements and potential HVAC system and operating savings, CarbonCast enclosure systems can help pay for themselves immediately.

Benefits of CarbonCast Enclosure Systems

• Full composite action for load bearing performance

• Continuous insulation to meet ASHRAE requirements

• Aesthetic versatility

Markets

• Multi-family

• Commercial

• Industrial

• Education

• Hospitality

• Student living

• Healthcare

• Institutional

Energy Efficient and Lighter in Weight

The exceptional bonding and strength of C-GRID trusses allow AltusGroup precasters to use less concrete and more insulating foam to reduce energy use and create lighter panels. They deliver superior insulation values for enhanced thermal efficiency and reduced energy expenditures.

Superior at Load Bearing

Vertical panels are available for both load bearing and non-structural applications. They can eliminate the need for perimeter columns and add to usable floor space.

Dry, Mold-Free and Non-Combustible

Unlike brick and block insulated cavity walls or brick with steel studs, concrete does not allow water to penetrate, eliminating the need for a rain screen design. CarbonCast panels have no voids or cavities where air or water can combine to support mold and mildew growth. When properly designed, they virtually eliminate the possibility for in-wall condensation. And the inherent fire resistance of concrete provides additional peace of mind.

Ideal for Occupant Comfort

CarbonCast High Performance Insulated Wall Panels provide an acoustic isolating environment. Very little sound is transmitted through the walls, which can provide an interior free of exterior noise. And the lack of cold spots provides a more comfortable environment.

Pre-Finished on the Inside Wall

These panels can have a troweled interior finish to eliminate the cost and time to install drywall or other surfaces. They are ready for paint or wall covering and are ultra-durable.

We are very excited about this innovative system and how it is changing the built environment for the better.

Find more information about CarbonCast here.

You think you know, but you have no idea - Part IV

By Mallory Combs, Marketing Intern

We recently sat down with the members of our Leadership Team to learn a little bit more about what makes them tick.  Here are some fun facts to help you get to know the team.

Bob MacDougall

Bob MacDougall, Controller
Bob does the work he does now because he enjoys working with individuals within the organization to maximize performance in their particular area, and he wanted to help coach others.  He was blessed to have a great mentor who knew how important the role of his job was in his life and others and passed down that perspective.  A song he likes, but rarely admits to liking, is Slow Hands by Niall Horan.  A hobby of Bob’s that very few know is that he likes to draw, especially replicating pictures he likes.  His other hobbies include kayaking, golf, four wheeling, and using ATVs.  We hope Bob’s last words are far down the road, but he would like to be able to say to his boys: “always love one another, even though I’m not here with you, I’m still with you.”  Finally, Bob’s spirit animal is a sloth because they methodically analyze every move they make.

You think you know, but you have no idea - Part III

By Mallory Combs, Marketing Intern

We recently sat down with the members of our Leadership Team to learn a little bit more about what makes them tick.  Here are some fun facts to help you get to know the team.

Mike Wolff

Mike Wolff, Vice President of Safety and Plant Operations
Mike does the work he does now because he loves Mid-States, as well as the team here, and he has always had a passion for quality and safety.  Something you may not know is that Mike has a degree in Police Science and was going to be a cop, until he decided he didn’t want to work every weekend and wanted to enjoy holidays off.  An artist he likes, but rarely admits to liking, is John Denver, who he grew up listening to on 8-track tapes.  Something he will never do again is touch a hot stove, because, for some reason, it hurts!  A time Mike has been tricked was on his first day here at Mid-States, when Dan Rippl tricked him in to running a wheelbarrow for most of the day because Dan told him it was the only way Mike could gain his respect.  Some hobbies of Mike’s that very few know may include that he used to participate in Black Powder Rendezvous, sleeping in teepees, and dressing up in buck skins.  He even once sewed an entire buckskin outfit out of deer hides himself.  His other hobbies include hunting and trapping, spending time with his family grilling out, going to swim meets, going to opening day of hunting season with his family, and riding his Harley with his wife.  We hope that Mike’s last words are far off, but he would want to thank God and his family for a wonderful life and feel like he impacted the world positively.  Finally, Mike’s spirit animal is a hawk, because it has a keen eyesight and can view obstacles and challenges in advance, as well as because it only takes what it needs to survive and doesn’t waste.  Also, it is precise in its calculations when taking game and always puts its young’s survival first.

Michael McNett

Michael McNett, Director of Information Technology
Michael decided to go into IT because at 17, he co-owned an ISP (Internet Service Provider) and he had a passion for helping users.  He originally wanted to be a broker, until he realized what they really do: “make people broke.”  Michael enjoys listening to Justin Bieber, but thinks Justin Timberlake is the better Justin, which I wholeheartedly agree with.  Michael enjoys traveling, has stock in the Snapchat market, and is currently on the Tesla waiting list.  One way Michael has proved his commitment to hard work is through his motivation to mix his own concrete and pour his driveway.  Although we hope Michael’s last words will be far off, he hopes they will be: “Weeeeeeeee!”  Finally, Mike’s spirit animal is a dolphin-owl.  Not really sure what that is, but we’ll take it!

Tune in for Part IV tomorrow - featuring Bob MacDougall, Controller.