Precast Solutions - March/April 2008 - (Page 6)

PERFECTING PRECAST One precaster recently adopted the new material for both factory and field patching of wall panels. Ecolite Concrete USA, Carlsbad, Calif., is the producer of a new construction system that precasts a hybrid wall of cellular concrete with integral steel stud framing. A significant element of Ecolite’s business is the ability to produce walls quickly; the product is strong and light enough to be stripped from the casting tables after overnight curing. Maneuvering large walls on a forklift through the factory interior, however, sometimes results in surface dings or edge damage. Ecolite began using the patching compound on edge and corner damage to improve the overall quality of its product. Its first-ever project was a 56-building training facility constructed for the U.S. Army Corps of Engineers. The client imposed strict quality standards, and the concrete had to have visually sharp edges to make good panel-to-panel joints. Using the new compound, nicked or spalled concrete edges were smoothed and straightened before they left the factory. RAW This parking structure features a highly visible superstructure of "raw" concrete. The surface is, in reality, a full skim-coat of patching compound that achieves an extremely smooth yet natural appearance. BEAUTY The job site was 45 miles from the factory in a remote desert location at the end of a rough, washboarded dirt road. The Ecolite panels made the journey without cracking, but edges and corners were vulnerable to damage. Field patching was successful on the job site despite high winds, extremely low humidity and temperatures reaching 120 F. While the concrete at the Stater Bros. project is painted, another Southern California project utilizes the material as an unpainted finish coat. The Nutwood Parking Structure at California State University, Fullerton, is a five-story, 780,000-square-foot building at the corner of the campus, one of the tallest and most visible profiles the institution presents to the surrounding community. It is partially faced with decorative screens of frosted glass and stainless steel. The concrete superstructure is prominently visible above, below and to the sides of these decorative additions. The concrete is finished with a smooth skim-coat of patching compound. Originally, the compound was applied only to fix problem spots. The appearance of the sacked sections was so impressive, however, that the decision was made to finish the entire structure with a “natural” unpainted concrete surface by skim-coating the entire building. It presents the appearance of an unusually smooth and even concrete of very pale gray; in the late afternoon sun, it is almost a cream white. At a distance, it might be mistaken for a paint finish, but at closer range, it has the softness of an unpainted surface. It blends well with the steel and glass decorative panels. SUMMARY Appreciation for the aesthetics of concrete continues to grow, increasing the demand for finishes with consistent textures. This is especially true of smooth finishes that feature the color and feel of concrete, but without the imperfections that often occur in the casting process. To meet this demand, patching methods and materials have improved. By broadening the range of available finishes, from rough and raw to sanded smoothness, producers are pushing forward the concrete aesthetic into more architectural uses and more markets. Michael Chusid, RA FCSI, is principal of Chusid Associates, an architectural materials and technology consulting firm. He serves on the American Concrete Institute’s Committee 124 – Concrete Aesthetics. He can be reached at www.chusid.com. For more information on WunderFixx, visit www.rapidset.com 6 PRECAST SOLUTIONS | MARCH/APRIL 2008 http://www.chusid.com http://www.rapidset.com

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Precast Solutions - March/April 2008 Contents Smooth Move Riding the Waves Comparing RCP With Plastic Pipe Cost-Value Analysis of Storm Sewer Pipe Concrete Testing On a Grand Scale Building Confidence

Precast Solutions - March/April 2008

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