Precast Solutions - November/December 2008 - (Page 12) The 525 lightweight precast panels were installed in just over three months. installed on site in just over three months after only five months of production time in the factory. McRoberts feels the panels went up quickly, especially considering the fact that progress was often sidelined by weather. “You can’t install a three-story concrete panel in high winds,” he points out. The inside surface of the panels consists of 16 gauge, 6-inch galvanized steel studs vertically spaced at 2-foot centers. This provided for easier and faster construction since the panels’ metal framing can be used for mounting interior gypsum board with no additional metal studs required. The precast panels are also virtually maintenance-free, no small consideration in a building that is 38 stories tall. Kamali says the Westin was his first experience with the panel system. “I think it’s a good product, and it’s cheaper than traditional (materials),” he says. “And you can have any shape and texture you want.” addressed this concern by providing a unique double caulk system with a thin backer-rod material. Chipping, cracking and warping are other concerns that give rise to architect and contractor anxiety, but strict quality control during every step of the manufacturing and delivery processes helps to allay these concerns. Another challenge is the color matching of the panels. In the case of the Westin tower, the panels feature two tones: a light acid wash and dark brown accents for trim around the window punches. The controlled environment inherent with precast concrete provides consistent results with each cycle of the manufacturing process. “To have the right architectural effect, the colors have to be correct,” notes Kamali. The Westin, which opened for business last November, includes 236 luxury guest rooms, more than 100 condominium units, heated indoor pool, fitness center, restaurant, more than 35,000 square feet of retail space and a 947-space parking garage. QUALITY CONTROL “SlenderWall was the right solution for us,” says Lou Haddad, Armada Hoffler’s president and CEO. “This is the tallest building in Virginia, so we didn’t want to experiment.” One of Kamali’s biggest concerns with the lightweight panel system was the waterproofing of the project’s façade. “The watertightness relies heavily on how well the sealant is installed and how durable it is,” notes Kamali. “The standard method of double-caulking a joint (with two standard backer rods) cannot be used, because the panel is too thin.” Kamali says Smith-Midland Corp. Deborah Huso is a freelance writer who covers home design and restoration, sustainable building and design, and home construction. 12 PRECAST SOLUTIONS | NOVEMBER/DECEMBER 2008 Courtesy Smith-Midland Corp.
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