Precast Concrete Designs - STM, SAN, ARCH, AIR
Precast Tilt Up Wall Panels
1. Structural Design:
Tilt-up panels act as vertical load-bearing elements, often serving dual functions—supporting roof or floor systems and providing lateral stability through diaphragm action. Key structural design considerations include:
- Load Resistance: Panels are engineered to resist vertical loads (dead, live, snow) and lateral forces (wind, seismic), both in the temporary (tilting and bracing) and final positions.
- Reinforcement: Reinforcing steel is detailed for flexural strength, shear capacity, and crack control. Common reinforcement includes welded wire mesh and deformed bars, with optional fiber reinforcement for shrinkage control.
- Connection Details: Embedded hardware allows for secure connections to foundations, roof structures, and adjacent panels. Connections are engineered to transfer forces while accommodating tolerances and movement.
2. Architectural Design:
Tilt-up panels offer broad architectural flexibility. The design process considers:
- Panel Dimensions: Height and width are typically limited by transportation, lifting capacities, and site constraints. Panels commonly range from 20 to 50 feet in height.
- Finishes and Formliners: Panels can be cast with a variety of surface treatments—integral color, exposed aggregate, embedded brick, or decorative formliners—achieving both functional and aesthetic goals.
- Openings and Reveals: Windows, doors, and aesthetic reveals are formed into the panels during casting, minimizing post-installation work and preserving architectural intent.
3. Constructability and Erection:
Tilt-up construction requires strategic design for ease and safety in handling:
- Panel Casting: Panels are cast horizontally on-site using a casting slab, with high attention to dimensional accuracy and surface quality.
- Lifting Design: Engineers specify lifting inserts and rigging details, considering panel weight, center of gravity, and stresses during lifting.
- Bracing: Temporary bracing systems are designed to stabilize the panels against wind and construction loads until permanent structural elements are in place.
4. Code Compliance and Quality Assurance:
Tilt-up wall panel designs adhere to applicable codes (e.g., ACI 318, ASCE 7, IBC) and industry best practices. Quality control during casting and erection is essential to ensure performance, especially for structural integrity, finish quality, and connection accuracy.
Precast Concrete Paving
Aircraft-rated precast concrete paving is a high-performance solution engineered for the extreme loads, durability demands, and rapid installation needs of airfield infrastructure such as runways, taxiways, and aprons. Designed to withstand heavy aircraft wheel loads, fuel and chemical exposure, and environmental stresses, these precast panels are typically reinforced or prestressed for strength and fatigue resistance. Precision joints, durable surface finishes, and high-quality off-site fabrication ensure consistent performance and long service life. Their modular design enables fast-track construction and easy replacement, making them ideal for both civilian and military aviation applications where downtime must be minimized.
Electrical Duct Banks
Aircraft-rated precast concrete electrical duct banks are engineered to protect and route critical electrical and communication conduits beneath airfield pavements, including runways, taxiways, and aprons. Designed to withstand the heavy wheel loads and dynamic forces from aircraft traffic, these precast systems offer superior strength, durability, and resistance to fuel, deicing chemicals, and extreme environmental conditions. Factory-controlled manufacturing ensures consistent quality and accurate conduit alignment, while modular sections enable rapid installation and reduced airfield disruption. Ideal for mission-critical infrastructure, aircraft-rated precast duct banks provide long-lasting, low-maintenance protection for essential airfield utilities.