Comparing Precast Concrete Panels: Superiors Walls vs. Precast Insulated Concrete Panels
Structural Precast offers custom precast concrete structures that are pre-insulated and satisfy architectural and engineering requirements. Precast concrete walls are concrete walls poured offsite in a controlled environment, properly cured and then delivered to site for quick install.
They can be built with Superior Walls (a unique, licensed technology) or traditional, precast insulated concrete panels (also known as sandwich panels) — and we offer both.
What you eventually choose for your project will depend on your needs, budget and preferences (and we’re here to help you sort that out).
But before we compare the two products, here’s a refresher on why you might choose precast concrete over traditional pour-in-place concrete, wood or steel structures:
Higher quality concrete: The quality control processes in manufacturing (less honeycombing and the proper curing of concrete in a controlled environment) means a higher quality product and longer-lasting structures, especially when compared to pour-in-place concrete.
Less onsite labour: This means fewer health and safety concerns on the job site, as well as improved site efficiencies — meaning fewer people, fewer issues.
Reduced number of trades on site: This is ideal for rural settings where trades and services aren’t readily available and for markets that lack skilled trades.
Longer construction season: Heating and hording are not required during the winter months with precast concrete products.
Speed up construction time: Precast concrete products can be built in advance and then stored offsite until needed.
Wide variety of architectural finishes: Precast walls come in a variety of colours, textures and patterns.
Longevity: Concrete structures outlast wood and steel structures. They don’t mold, warp or rust. This reduces ongoing maintenance and operational costs.
Integrated: With precast concrete wall systems, the structure (or load bearing component) can be integrated with the insulation and the exterior finish. As a result, there’s less fussing and messing around on site. The walls, insulation and structure are all “integrated” into one element. Wood or steel structures will require multiple steps and more time to construct.
So, how to choose a precast concrete wall? Consider the pros and cons of each.
Superior Walls:
Pros:
They cost less (usually 30% to 40% less than precast insulated concrete panels).
The inside of the wall is unfinished, making it easy to run electrical and plumbing, and then finish it off with drywall.
The wall is insulated and requires no vapour barrier, and with galvanized steel facing, the drywall is simply screwed to it.
The walls weigh less, so they are more efficient and therefore less costly to transport.
It’s possible to flip the wall around so that the concrete finish is on the inside and then you can finish the exterior with your choice of material or product, including inexpensive siding.
Superior Walls are widely adopted in the U.S. market and their use is growing in western Canada (currently more than 300 builders use them.
Cons:
The inside of the wall is unfinished (in some commercial applications, it’s better to have a concrete interior because it’s durable for say, a chicken barn or car wash).
The wall can only withstand approximately 7,500 lbs per linear foot of pressure (precast insulated concrete panels can be manufactured to hold much more weight).
They are limited to the height of a continuous unsupported vertical wall of approximately 20 feet, which is a two-storey building.
Precast Insulated Concrete Panels (sandwich panels):
Pros:
The modular, pre-fabricated product is widely understood and accepted.
They are versatile and can handle significant structural loads to form the structure of the building, or can be used as a “cladding” around the building with a steel or concrete superstructure.
They offer concrete on both the inside and outside of the building, so there are no extra costs to finish the inside of the building.
They can span significant unsupported vertical wall heights up to 65 feet (for higher structures beyond 20 feet, concrete sandwich panels have to be pre-stressed to handle the shear forces).
They can be built in various thicknesses to vary the R-value of the wall and its load potential.
Like Superior Walls, precast insulated concrete sandwich panels are low maintenance, insulated and very durable — concrete structures can last for hundreds of years.
Cons:
The inside is solid concrete, so if you need to run electrical, you can run conduit inside the concrete (but it’s more costly and challenging).
With plumbing, you’ll have to leave it exposed or build a “pony” wall to conceal it (which adds to finishing costs).
The wall is more expensive to build due to more concrete and heavier, so there will be more costs associated with trucking and installing it.
Continuous insulation can be achieved (but it’s also more challenging and costly).
Ready to learn more about these two products? Get in touch and we’ll help you choose the precast concrete product that works best for your needs (maybe it’s a combination of the two).
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