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carboncastCommercial Wall Systems and Parking Structure Systems 03 45 00/ALT

BuyLine 5587

precast concrete

altusgroup®

P R E C A S T I N N O VAT O R S

build greensave green

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CarbonCast $ $ – $ $ $ $ $ � � � � � �

Precast $ $ – $ $ $ $ $ � � � � � �

Tilt-Up $ $ – $ $ $ $ $ � � � � � �

Cast-in-Place $ $ $ – $ $ $ $ $ $ � � � � � �

Masonry $ $ – $ $ $ $ $ $ $ � � � � � �

Metal Siding $ $ $ $ � � � � � �

Glass Curtainwall $ $ $ $ $ $ $ $ � � � � � �

Brick Curtainwall $ $ $ $ $ $ $ � � � � � �

EIFS Curtainwall $ $ $ $ $ $ � � � � � �

Metal Panel Curtainwall $ $ $ $ – $ $ $ $ $ $ $ $ � � � � � �

� Poor � Fair � Good � Excellent

2

Introduction to CarbonCast/C-GRID 2–3

CarbonCast Building Systems 4–7

� Component Selection Chart 4

Commercial Systems 4

� Architectural Panels 5

� Pretopped Double Tees 5

� High Performance Insulated Wall Panels 6

Finishes and Design Options 7

LEED Certification 8

Technical Requirements 8

About AltusGroup 8

Relative Relative Relative Speed Light Impact InsulationInstalled Cost Life Cycle Cost of Construction Weight Resistance Performance Durability Sustainability

Contents CarbonCast/C-GRID

1-866-GO-ALTUS

Enclosure or Decking Systems

The Precast AdvantageFor decades, architects and engineers havedepended on the strength, durability and designpossibilities of precast concrete to achieve:� Virtually unlimited aesthetic options � Outstanding fire and impact resistance� Excellent thermal efficiency and weather tightness� Superior quality and consistency � Fast-track construction � Low maintenance and life cycle costs

AltusGroup,® a nationwide consortium of more than adozen leading precasters,brings you CarbonCast,® the first national brand of precast

concrete and one that is revolutionizing the engi-neering and design of precast components andstructures.

CarbonCast adds even greater long-term durability, lighter weight, improved steady-stateinsulating properties and greater sustainabilityto the list of precast benefits.

Innovative CarbonCast uses conventional steelfor primary reinforcing and C-GRID® resin-bondedcarbon fiber grid for secondary reinforcing andshear transfer. It is the first major innovation inprecast concrete in more than half a century,since the development of prestressed precast.CarbonCast components reinforced with C-GRID are:� Thinner and up to 66 percent lighter with some

products � Can reduce foundation, structure and seismic

connection loads� Lower shipping and erection costs

� Stronger and more durable � Carbon fiber has over four times the tensile

strength of steel reinforcing

� More corrosion-resistant� C-GRID won’t rust, corrode or cause staining

or spalling� Minimizing shrinkage cracks up to 50 percent

better than steel mesh

In addition, CarbonCast wall panels are energyefficient, with higher insulation values.� Panels are thermally efficient and deliver

steady-state R values that are equal to thesum of all the parts that make up the paneland in many areas of the country are evenhigher due to the mass of the panel

� Higher steady-state R-values are achieved inthinner wall sections

� Cold spots created by solid concrete or steel reinforcing are eliminated

As a “green” building material, CarbonCast supports sustainability.� Made with local materials including industrial

and post-consumer waste� Uses less forming material and concrete� Reduces truck trips, site congestion and

disruption

On their own, these are all significant advancements—but they also add up to a more cost-effective building material.� Reducing material, handling, shipping and

erection costs� Resulting in durable, energy-efficient buildings

with lower operating costs

How CarbonCast Compares

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The Difference is C-GRID InsideC-GRID® is the “enabling technology” that allows CarbonCast® to be thinner, lighter, more durable and less costly than conventionalprecast. Developed by Chomarat NA (formerly TechFab, LLC), non-corrosive C-GRID has a tensile strength of 250 KSI. Carbon fiberhas over four times the strength of steel reinforcing.

C-GRID is an epoxy-coated composite grid made with cross-laid carbon fiber. Until now, carbon fiber has been limited to applica-tions where low weight and high strength are imperative, such as aerospace and sports equipment. Only since the developmentof industrial-grade carbon fiber materials and new fabric manufacturing technology has carbon fiber become feasible as aneconomical reinforcing material for new construction.

While C-GRID has a component cost several times the cost of the steel it replaces, it enables changes in precast design thatmake CarbonCast components competitive with conventional precast components—before superstructure and energy-related savings are factored in. For example, C-GRID requires only 1⁄4" of concrete cover compared with steel reinforcing, which generallyrequires 3⁄4" to 11⁄2" to protect it from moisture-induced corrosion.

C-GRID also creates a fully composite section between the outer and inner wythes of insulated sandwich wall panels so that theycan be thinner or taller. C-GRID controls shrinkage cracks up to 50 percent more effectively than steel mesh because it is placedcloser to the surface and has a more closely spaced mesh pattern than steel

C-GRID: The Enabling Technology

The Cover Story: With Concrete, Less is MoreWhile conventional precast requires an exterior face thickness of two to threeinches to minimize steel reinforcing corrosion, C-GRID allows a practical reductionof face thickness to as little as 13⁄4". As the carbon fiber used to make C-GRID is100 percent inert, the exterior concrete faces of CarbonCast products function100 percent for structural integrity, rather than corrosion protection. Not onlydoes this offer the benefit of lighter weight, better-insulating components, but itlets you use premium aggregates and color additives, which could be costly inthicker, conventionally reinforced precast components.

Exterior face

Carbon fiber grid requires 66 percent less concrete coverthan steel mesh.

ACI minimum required for steel reinforcement

Theoretical minimum required cover for C-GRID reinforcement

3www.altusprecast.com

03 45 00/ALTBuyLine 5587

AltusGroup: Innovators in Precast TechnologyCarbonCast components are available fromAltusGroup, the first-ever national partnership of precast concrete manufacturers, with coast-to-coast availability, consistent quality and uniform design standards no matter whereyour project is located.

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CarbonCast Commercial Systems

Characteristics

Nonstructural � � �

Structural � �

Thickness/Depth 6–12" NA Up to 12" 18–34"

Width/Height (max.) Up to 15' NA Up to 15' 10–16'

Length (max.) Up to 45' NA Up to 55' Up to 60'

R-Value Up to 16 NA 13–30 NA

Fire Assembly Rating Up to 2 hr NA Up to 3 hr 2 hr

Frame Construction

Precast � � � �

Steel � � � �

Pre-Engineered � �

Cast-in-Place � �

Masonry �

Uses

Parking � �

Office � � �

Educational � � �

Institutional � � �

Correctional Facilities � � �

Laboratory � � �

Stadiums � � �

Retail � � �

Industrial/Warehouse � � �

Hotel/Motel � � �

Dormitory � � �

Apartment � � �

Condominium � � �

Architectural Wall High Performance Pretopped Cladding Panels Components Insulated Wall Panels Double Tees

4 1-866-GO-ALTUS

Commercial Systems

CarbonCast Component Selection Chart

Changing the Way You Design with PrecastCarbonCast® components are available in many shapes andsizes, which can be combined into systems to addressalmost all design requirements. Even your most imaginativedesigns can be realized through AltusGroup’s standard orcustom solutions and carefully controlled factory productiontechniques.

Lightweight CarbonCast components:� Reduce structure loads� Accelerate occupancy—install in virtually any kind

of weather� Enable weather-tight, thermally-efficient panels with

performance up to steady-state R-35� Have superior resistance to cracking and the effects

of corrosion

Thin CarbonCast panels are also suitable for interior claddingof large public areas, creating opportunities for a multitudeof interior surface treatments, finishes and textures.

Symphony House

The Heldrich

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Architectural PanelPrimary Vertical Rib-A

Architectural PanelSecondary Vertical Rib

Pretopped Double Tees

Architectural Cladding Panels CarbonCast® nonstructural wall systems can be used in combination withboth steel and cast-in-place structural systems, and can even have thin brickor stone veneers. They support all glazing systems and work seamlesslywith a wide range of other building materials, such as brick, tile and stone,for an expressive facade that will stand the test of time.

6"–12" thick CarbonCast Architectural Cladding Panels feature a C-GRID®

reinforced exterior face as thin as 13⁄4 inches and a structural rib design thatdelivers value-added insulation performance up to R-12 steady state. Inaddition, lightweight, insulated CarbonCast can significantly reduce buildingsuperstructure and operating costs.

This patent-pending design delivers:� Panel weights of up to 66 percent less per square foot than

conventional precast� Composite steady-state R-values of up to 12

Architectural ComponentsCarbonCast nonstructural architectural cladding systems provide weather-tight, durable, low-maintenance facades for steel frame or cast-in-place structures. Components include horizontal and vertical panels and applied cladding elements suchas column covers, cornices and soffits.

CarbonCast panels, which can be as thin as 13⁄4", can also be an excellent choice for screen walls.

CarbonCast’s unique corrosion-resistant properties enhance precast perform-ance as primary floor and roof elements for outdoor parking garages or decks.

Conventional steel reinforced decks exposed to vehicular traffic and weatherare subject to corrosion from moisture and the degrading effects of salt andde-icing chemicals.

Not so with CarbonCast. CarbonCast Pretopped Double Tees can also incor-porate field-installed precast curbs to direct water to drains, or they can becast to receive field-applied washes/pour strips. Double tees with precastcurbs and welded end connections for seismic performance are recommendedin many areas of the country. Cracking can lead to corrosion and adverseeffects such as leaks, spalling and rusting of diaphragm reinforcing that canstain decks, increasing maintenance and repairs.

C-GRID’s unique non-corrosive properties also mean that CarbonCast DoubleTee flanges can be made with less covering concrete. Weighing up to 12 percent less than conventional precast, CarbonCast can significantlyreduce structure costs. Thinner CarbonCast Double Tee flanges result in:� Reduced foundation loads in most cases� Supporting elements/connections designed

for lighter loads and/or wider bays� Shallower tees that enable increased

clearance under tees or decreased structure heights

� Lower shipping and erection costs� Less maintenance, better

long-term performance

CarbonCastPretopped Double Tees with C-GRID.

CarbonCast Pretopped Double Tee

CarbonCast Pretopped Double Tee with Curbed Deck

Architectural Panels & Components

CarbonCast ArchitecturalCladding Panel with continuous foam insulation.


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6 1-866-GO-ALTUS

CarbonCast® High Performance Insulated Wall Panels are precast concretesandwich wall panels that are 8' to 15' wide, up to 55 feet high and 8" to 12"thick. They can be oriented vertically or horizontally.

C-GRID® carbon fiber shear trusses connect the inside and outside precastconcrete wythes of the wall. When used in conjunction with pilastersinternal to the panel, they create a fully composite sandwich panel thatbehaves structurally as if it were solid concrete. CarbonCast HighPerformance Insulated Wall Panels can be used in both non-load-bearingand load-bearing applications. In load-bearing applications, panels can support multistory floor and roof loads, eliminating the need for perimetercolumns and footings.

C-GRID shear trusses have relatively low thermal conductivity.CarbonCast High Performance Insulated Wall Panels incorporate rigidfoam, delivering a panel with a steady-state R-value of R-13–35 or more.They can also can weigh less than conventional panels, which meansthey can be transported farther and are more LEED-friendly.

CarbonCast High Performance Insulated Wall Panels can be used any-where conventional precast sandwich panels are used, and in applica-tions where conventional precast might not be considered such as areplacement for brick and block cavity walls. Typical end use applicationsinclude schools, data centers, aquariums, stores, theatres, airport terminals, food processing operations, cold storage facilities, flex-officesand warehouses, maintenance depots and correctional facilities.

High Performance Insulated Wall Panels

CarbonCast High PerformanceInsulated Wall Panel with continuous foam insulation.

High Performance Insulated Wall Panelwith Pilaster

Cobb County Performing Arts Center

New Jersey Aquarium

Wall Panel Window/Door Head & SillHorizontal Section

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Finishes and Design Opportunities

CarbonCast Finishes Cost Less and Look Better LongerCarbonCast® products come in an almost lim-itless palette of natural colors and finishes tofit any project. Multiple materials and surfacetreatments can be combined in the samestructure—even in the same component—and finishes can be matched to existingstructures.

In addition, CarbonCast offers expandeddesign opportunities beyond conventionalprecast. Since CarbonCast components utilize up to 66 percent less concrete,expensive pigments and aggregates becomemore affordable ensuring your design visionremains intact for decades. And CarbonCast

can help preserve the building’s appearancefor years.

Since all components are manufactured byAltusGroup precasters under factory-controlledconditions, you are ensured uniform colors, finishesand textures, no matter where your project islocated. CarbonCast components also offergreat interior finish options—especially inlarge public spaces or in areas with high maintenance requirements

AltusGroup is expert in assisting architects toselect the CarbonCast mix and finish thatmaintain optimum strength and durability whileensuring the desired visual appearance.

Factory AccentsReveals � � �

Precast Trims � � �

SurfacesPrecast � � � �

Molded Brick � � �

Molded Stone � � �

Molded Clapboard � � �

Factory VeneersTile � � �

Thin Brick � � �

Thin Stone � � �

Factory FinishesClear Sealer � � �

Paint � � �

Stain � � �

Stucco � � �

Acid Wash � � �

Light Blast � � �

Medium Blast � � �

Heavy Blast � � �

Exposed Aggregate � � �

Honed � � �

Polished � � �

Field Finishes & AccentsSynthetic Trims � � �

Clear Sealer � � �

Paint � � � �

Stain � � � �

Stucco � � �

Broom Finish � �

Architectural Architectural Wall High Performance Pretopped Cladding Panels Components Insulated Wall Panels Double Tees

Finishes Chart


Georgia State University Dormitories

Edward Jones headquarters (rendering)

University of North Florida Student Union (rendering)

Georgia State University Dormitories

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PO Box 10097Lancaster, PA 17605

866 [email protected]

altusgroup®

CarbonCast Contributes to LEED Certification CreditsCarbonCast is a green product that provides a multitude of benefits for architects and owners seeking LEED® certification. Depending on the application, CarbonCast products can deliver up to31 credits, exceeding the 26 required for certification.

CarbonCast wall systems optimize energy performance, contributing up to 10 extra credits in structures that outperform minimum ASHRAE requirements. Light-colored precast reflects solarheat and reduces cooling loads. Since light-colored facades also reflect lighting better, fewerfixtures or lower wattage fixtures are required. In addition, the thermal mass of concrete canmoderate heating and cooling peaks, lowering HVAC requirements and energyuse.

CarbonCast diverts construction waste by returning it to the construction process and reusing orrecycling many of its constituents.

Most CarbonCast products are manufactured locally or regionally, with virtually all materialsextracted from within a 500-mile radius of project sites. Lighter CarbonCast reduces transportationfuel consumption, takes up less space on site and goes up faster, which reduces fuel wastagefrom cars detouring construction sites or idling in traffic.

CarbonCast products can reduce indoor chemical and pollutant sources, and produce no dust or airborne contaminants and can be left unpainted, avoiding VOC-emitting paints, stains orsealants. Outdoor moisture does not penetrate or condense on the interior of 100 percent thermally efficient CarbonCast Wall Panels.

AltusGroup, a first-ever partnership of the industry’s largest precasters and Chomarat NA(formerly TechFab, LLC) was formed to make CarbonCast—and other future innovations—available throughout North America.

AltusGroup is a single point of contact for:� Innovative products—pooled research resources, extensive testing and the backing of trusted

industry leaders� Coast-to-coast product availability—more than 30 manufacturing and sales locations in the US� Consistent superior quality—a national network of PCI certified plants ensuring

uniform performance standards� Superior technical service and support—a central source for complete technical

information with more than 350 local specification-oriented professionals to help with designand construction challenges

Precast Concrete ACI 318; PCI MNL-116; PCI MNL-117

Steel Reinforcing ASTM A706; ASTM A82; ASTM A185; ASTM A496;ASTM A497; ASTM A416

Structural Welding AWS D1.1; AWS D1.4

Foam IBC 2603; UBC 2602

Carbon Fiber Reinforcement ACI 440.2R-08

Thermal Performance ASHRAE 90.1

Material Applicable Codes, Standards or Guidelines

Technical Requirements

AltusGroup Producers:Oldcastle Precast, Building Systems Baltimore, Md.; Morrisville, Pa.; South Bethlehem, N.Y.Spokane, Wa. (Central Pre-Mix Prestress Company)www.oldcastlesystems.comHigh Concrete Group LLCDenver, Pa.; Williamsport, Pa.; Springboro, Ohio; Paxton, Ill.; Buena, N.J.www.highconcrete.comMetromont CorporationAtlanta, Ga.; Greenville, S.C.; Charlotte, N.C.; Nashville,Tenn.; Richmond, VA.; Polk County, Fla.www.metromontusa.comChomarat North America, LLCAnderson, S.C.www.chomaratna.comGate Precast CompanyOxford, N.C.; Monroeville, Ala.; Kissimmee, Fla.; Jacksonville, Fla.; Nashville, Tenn.; Winchester, Ky.; Hillsboro, Tex.www.gateprecast.comBlakeslee PrestressBranford, Conn.www.blakesleeprestress.comEncon UnitedTooele, Utahwww.eprecast.com Enterprise Precast ConcreteOmaha, Neb.www.enterpriseprecast.comGage PrecastSioux Falls, S.D.www.gagebrothers.com GPRM PrestressKapolei, Hawaiiwww.gprmp.comHeldenfels Enterprises, Inc.San Marcos, Tex.www.heldenfels.comKnife RiverHarrisburg, Ore.www.kniferiverprestress.comShockey Precast GroupWinchester, Va.; Fredericksburg, Va. www.shockeycompanies.comWells Concrete ProductsWells, Minn.www.wellsconcrete.com

Innovation Partners:

A.L. Patterson, Inc. www.alpatterson.comBASF Admixtures www.basf-admixtures.comEndicott Clay Products Company www.endicott.comEssroc Italcemeni Group www.essroc.comHigh Concrete Accessories www.highconcreteaccessories.comInnovative Brick Systems, LLC www.mbrick.comInsulfoam www.insulfoam.comJVI www.jvi-inc.comLafarge North America, Inc. www.lafargenorthamerica.comMeadow Burke Products www.meadowburke.comOwens Corning www.owenscorning.comSika Corporation (USA) www.sikacorp.comToho Tenax www.tohotenaxamerica.comZoltek Corporation www.zoltek.com

For more information about AltusGroup, CarbonCast precast concrete components and the C-GRID technology, call 866-GO-ALTUS or visit www.altusprecast.com.

C-GRID is a trademark of Chomarat NA

CarbonCast is a trademark of AltusGroup

A Unique Innovation. An Unprecedented Partnership.

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