8 PRECAST SOLUTIONS | WIINTER 2007

TECH BRI EF
I
n a world where one can never be too thin, too
strong or too beautiful, thin-shell precast concrete
is a step closer to that ideal. In the past, the heavy
weight of concrete and the costs associated with
lifting and transporting that weight have limited the
use of precast. Innovative fabrication techniques,
however, now make it possible to reduce the weight of
precast concrete walls.
This new breed of precast is accomplished through
hybridization, combining the best characteristics of two
separate building materials. Thin-shell precast panels,
also known as studcast precast, are made by
marrying as little as 2 inches of concrete to light-gauge,
cold-formed steel framing. The concrete provides a
durable and attractive skin available in the designers
choice of color and texture and
the steel studs
provide the
structural bones of the wall.
The steel studs are assembled into panels and then
integrally connected to concrete during the precasting
process. Together, they create a wall that is both more
and less than the sum of their parts:
Because the two materials create a structural
composite that can outperform either material used by
itself. The steel resists axial and transverse loads, and the
concrete stiffens the steel and provides a diaphragm to
resist in-plane forces. This means thin-shell precast can
be used for structurally efficient load-bearing walls as
well as for cladding and curtainwalls.
Thin-shell precast uses up to 75 percent less
concrete than the 4 to 8 inches of concrete thickness in
conventional precast panels. This means a thin-shell
wall weighs about 35 pounds per square foot (psf)
including the framing instead of 100 psf. And if a cellular
concrete mix is used, the wall can weigh as little as 12
psf. With these reduced dead loads, a precast thin-shell
wall weighs less than a concrete masonry wall and can
compare even with construction materials like stucco
on wood framing. The light weight affects the entire
structure, saving money and materials from the
foundation upward.
Precast construction speeds up project schedules by
fabricating walls off site while the foundations and
superstructure are being prepared. Prefabrication also
allows a building to be enclosed sooner so
other trades can work
out of the weather.
Thin-shell systems have additional time advantages.
Construction, for example, is simplified because one
can use lighter weight equipment to lift the panels or
opt to use fewer but larger panels. Panels as big as 16
feet by 40 feet have been used. Either approach can
reduce the size or number of connections that have to
be made between a wall and the adjacent construction.
Furthermore, thin-shell walls eliminate the
requirement to install furring on the inside of the walls.
Thats because a thin-shell walls metal studs provide
ready-made cavities for insulation and utilities and are
ready for the attachment of interior finishes. Eliminating
wall furring also reclaims several inches of floor space
THIN IS IN
NEW HYBRID THIN-SHELL PRECAST WALL
SYSTEMS DO MORE AND LESS.
BY MICHAEL CHUSID, RA, FCSI
PHOTOS COURTESY METAL STUD CRETE
Precasters captured the neo-
classical architecture of the
Huntington Library and
replicated it for the new
Munger Research Center on
the Librarys San Marino,
Calif., campus. Read more
about this project (Blending
In) in the Precast Solutions
Weekly archive,
www.precast.org/weekly.
around the entire perimeter of the building to increase
the buildings net usable area.
These economies make thin-shell cost-competitive
with other forms of construction, which have previously
dominated many markets, including housing,
commercial, industrial and institutional buildings. Added
to this is a long list of other benefits.
Concrete and steel hybrid panels score high marks
for safety and durability. There are a number of tested
designs for fire-resistant thin-wall systems. Both steel
and concrete are non-combustible, enabling a building
owner to qualify for lower fire insurance underwriting.
Structurally, the composite panels can be engineered
to survive hurricane-force winds. And their seismic
resistance is improved by the reduced mass of the thin-
shell walls. In addition, concrete and steel are
impervious to mold and termites, and galvanized steel is
generally used for corrosion resistance.
Moreover, the potentially larger panels have fewer
panel joints to seal against air and moisture infiltration,
improving thermal control. A wide variety of
architectural finishes and surface details are available.
Environmentally, thin-shell systems are suitable for
green construction and can help a project qualify for
credits under the U.S. Green Building Councils LEED
program. Consider:
Recycled Content: Most steel produced in this
country has significant recycled content. And fly ash or
WIINTER 2007 | PRECAST SOLUTIONS 9
other supplementary cementitious materials can be
used in concrete. When the building is eventually
demolished, the steel and concrete can be readily
separated for recycling.
Locally Available Products: Most precast panels are
locally produced using locally extracted raw materials.
Energy Efficiency: Studs up to 6 inches deep can be
used to accommodate additional insulation. Studs are
also available with open webs that decrease thermal
losses through the steel. More large panel sizes,
possible with thin-shell systems, decrease the number
of joints in a wall to reduce air infiltration and exfiltration.
Innovation Credit Greenhouse Gases: By cutting
the quantity of concrete used for precast, thin-shell
reduces the amount of CO2 emissions a major
greenhouse gas associated with the portland cement
produced for the project.
Innovation Credit Transportation: While the weight
of conventional precast typically limits the number of
panels that can be loaded on a truck, lighter weight thin-
shell precast allows two or more times as many panels
per truckload. This dramatically cuts fuel consumption, air
pollution, tire wear and other environmental impacts.
While some thin-shell systems have a two-decades-
long track record of successful use, recent innovations
and the desire for better and more affordable buildings
have sparked growing interest in the concept. The
accompanying articles look at two different systems
that suggest the range of opportunities offered by thin-
shell precast. They differ in the kind of concrete they
employ and the way they attach concrete to steel. This
in turn creates different strengths and options. The
more closely you examine the details, the more
possibilities you find.
See the Spring 2007 issue of Precast Solutions to
learnb about Ecolite, a new type of studcast precast
made with lightweight cellular concrete for improved
thermal properties and fire resistance.
10 PRECAST SOLUTIONS | WIINTER 2007
Michael Chusid is an architect and Fellow of the
Construction Specifications Institute and serves on the
American Concrete Institutes Committee 124
Concrete Aesthetics. His company, Chusid Associates,
consults on the development of innovative building
products and technologies. He can be reached at
www.chusid.com.
Above: Panels at the Huntington
Library had 30-inch-deep returns
at windows to create the illusion
of massive walls.
Below: The 14-story Beaumont
Condominiums is the tallest
building in its section of
Philadelphia, clad in
thin-shell precast
panels.
WIINTER 2007 | PRECAST SOLUTIONS 11
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