Innovative Precast Technology: High Tech, High Strength ... and Low Weight

When people think of high-strength, low-weight carbon fiber, images of fighter jets, racing cars, tennis racquets and bicycle frames usually come to mind.

But apply carbon fiber’s properties to precast concrete wall panels and floor decks for multi-family residential units and you can realize reduced weight while improving strength, insulation and long-term durability.

That’s the innovation called CarbonCast™. Introduced earlier this year by AltusGroup™ (www.altusprecast.com), the first-ever national partnership of precast concrete manufacturers, CarbonCast precast products use C-GRID™, a non-corrosive carbon fiber grid, for secondary reinforcing rather than conventional steel mesh. Despite its light weight, high-strength, ultra-durable C-GRID has superior tensile properties compared to steel.

Developed by TechFab, LLC (www.techfabllc.com) of Anderson, S.C., C-GRID is non-corrosive. It requires only 1/4" of concrete cover to be effective, compared with 3/4" to 3" of cover for steel reinforcing. Less concrete cover translates to lower weights. At the same time, thinner C-GRID-reinforced precast sections will not rust, so CarbonCast surfaces will not stain or spall as sometimes occurs with conventional steel reinforcement.

The reduced weight (up to 60% lighter for wall panels) and section thickness of CarbonCast translate to lower transportation and erection costs. The improved insulating properties of CarbonCast panels lead to more energy-efficient buildings with lower operating costs, making CarbonCast products a suitable choice for environmentally friendly designs.

CarbonCast precast products deliver the long-recognized benefits of factory precasting. For example, wall panels are available in a variety of shapes, colors, finishes, and veneers rivaling almost any field-applied finish. Compared with stick-built residential, precast concrete is virtually impervious to vermin and insect damage. Plus, precision-manufactured precast products are delivered directly on-site and ready to erect, avoiding the scheduling problems associated with coordinating various trades.

To date, almost three dozen commercial projects representing over 1 million square feet of CarbonCast product are either completed, under construction or in the design phase. One such application is a multi-family housing project for Habitat for Humanity in Yonkers, N.Y.

As carbon fiber grid gains exposure among the architectural and specifying community, it is expected to earn rapid acceptance as a desirable, performance-enhancing, affordable alternative to conventional steel mesh reinforcement — especially in the production of precast sections for multi-family residential projects.

More information about AltusGroup and CarbonCast is available at www.altusprecast.com, or by calling 866-GO-ALTUS.

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