There’s no question that concrete is one of the longest-lasting and most economical building materials. The fact that concrete actually gets stronger over time makes it a winner over other construction materials, like wood, for example. Believe it or not, there are actually 23 different types of concrete used in today’s modern construction industry. These types can be used in different applications to achieve a variety of results. But today, it’s the process we want to discuss: Precast concrete versus cast-in-place (CIP) concrete. What’s better? To answer that question, let’s take a look at each process, the advantages of each and, of course, your desired outcome.

What is Precast Concrete? 

Precast concrete products are cast at a factory. The concrete, a mixture of cement, water, aggregates and admixtures, is placed into a form and cured before being stripped. These products are then delivered to the construction site for erection into place. Precast products can include concrete bricks or stones, structural components and wall panels, to name just a few.

What Are the Advantages of Precast Concrete? 

The benefits of precast concrete are most notably speed, durability, efficiency and quality. However, perhaps the most important characteristic is the material’s flexibility. Precast concrete can be used in a variety of applications making it appealing to architects, developers, general contractors and designers alike.

Working with precast concrete offers the following advantages:

• Speed: Not only can products be cast while foundation work is in progress, but precast concrete components can be cast and erected year-round regardless of weather conditions.
• Durability: Concrete is by nature a highly-durable material that is resistant to wear, weather and damage.
• Energy Efficiency: Concrete’s high thermal mass conserves energy, and the use of insulated panels only enhance that attribute.
• Environmentally Friendly: Precast concrete is clean and waste-free, and the addition of by-products reduces requirement for cement in the mix, as evidenced by the ability to obtain LEED certification.
• High Quality: Since products are cast in a factory, quality control is very high and allows for a single source provider.
• Aesthetic Flexibility: Precast can mimic granite, limestone, brick and other masonry products and can be finished in variety of textures and colors.
• Design Flexibility: Precast concrete members can handle higher loading and longer span capabilities providing more flexibility with office and parking structures.

What is Cast-in-Place (CIP) Concrete? 

CIP (or site cast) concrete is prepared at local plants for construction site delivery via trucks with revolving drums. Once the concrete arrives, the walls and slabs are cast at the site in the formwork. CIP concrete requires a strength test and additional time for curing on-site. Sometimes it can be hard to control the mix when weather conditions are a factor.

What Are the Advantages of CIP Concrete? 

Strength, reduced transportation and insulation are the primary benefits of site cast concrete. While concrete is an inherently strong material, CIP concrete is preferred for laying foundations and basement walls. It is also relatively resistant to structural damage due to earthquakes, floods or other natural disasters. Since site cast concrete is cast at the construction site, there is no need for transportation of finished products. On the flip side, this process requires more labor onsite to ensure proper and timely pouring, molding and curing. Finally, since this type of concrete is poured on-site, there is a fewer occurrence of natural cracks or gaps between walls leading to insulation properties that extend to insects, mold and mildew.

Designing with Precast Concrete 

Developers, architects, designers and contractors come together on a building project to achieve a desired outcome. Usually each party has several challenges to overcome and the desired outcome is a cohesive look and feel that capitalizes on function and efficiency. Here’s some common issues that may arise during the planning process and how precast concrete can offer a solution. Check out the Precast/Prestressed Concrete Institute (PCI) design resources for more information.

How can I ensure sufficient structural support for computer and storage systems in an office building or distribution center? High-strength flooring provides support for heavy loads now and in the future. Take a look at this data center.

Can using precast concrete increase energy efficiency? Yes, the material’s inherent thermal mass helps regulate temperatures but insulated precast concrete sandwich panels provide added energy efficiency due to insulation in the core.

How do I minimize congestion and safety concerns on-site and in the general vicinity during construction? Since precast concrete products can be delivered to the site as needed for that day’s erection, staging areas can be arranged nearby ensuring less traffic on-site and less congestion in the vicinity.

Can I create tall, open interiors with precast to allow for flexible merchandising space? Yes, architectural precast concrete panels can be designed to provide high ceilings. Check out this retail project.

What about delivery docking space? How can I accommodate trucks? Precast concrete panels’ capability to be cast in 12-feet widths or wider allows docking doors to be built into a single panel, providing inherent stability and fast erection. Take a look at this cargo center.

Can precast concrete materials help me create a design that complements surrounding buildings while also meeting brand requirements? Architectural precast concrete panels use colors, textures, reveals, finishes, form liners, or thin-brick insets to match any needed design style. These looks can be used for warehouse type retailers, additions to malls, stand-alone stores and more.

How can I design open interior spaces to maximize parking layout and provide a secure environment? Double tees can span long distances to eliminate columns and provide unobstructed view through the levels. Moment frames, k frames, lite walls and other unique structural supports can open interiors and smooth traffic flow. Check out this open parking deck.

How do I create high fire resistance? Precast concrete’s non-combustible composition minimizes the spread of fire, while compartmentalization design techniques provide time for detection, evacuation and suppression.

How can I create long-span areas like gymnasiums and pools? The use of precast hollow-core slabs and double tees can span long distances to minimize or eliminate columns where needed. Take a look at this recreation center.

What about noise? Can using precast concrete materials control acoustics? Yes, precast concrete wall panels, especially insulated panels, minimize noise between units.

I’m working with strict zoning requirements. How can I minimize floor-to-floor heights? Hollow-core slabs can serve as a combined ceiling/flooring unit, reducing the building’s height.

There are many factors to consider when choosing materials – and partners – for your project. Precast concrete continues to evolve as designers expand the applications of the material. ATMI Precast is a full-service precast construction company. We service a broad spectrum of project types, from mid-rise office to residential and parking and look forward to working with partners who will push the boundaries and create innovative projects. Long recognized as a leader in the field, ATMI Precast has earned customer recognition for our reliable performance, quality and service throughout the precast concrete construction process.

Choosing precast concrete for your construction project can directly impact your bottom line throughout all phases of construction and for everyone involved. One of the many benefits of precast concrete is the inherent versatility and reliability of the product itself, which makes it a top choice for a variety of markets, including: industrial, institutional, corporate, parking decks, residential, and retail.

In order to pull off a large-scale development, the owner, architect, general contractor, and engineer must all work together to stay on time and on budget while achieving a functional, aesthetically-pleasing building that meets several guidelines and standards. Learn how using precast concrete can save you money before construction begins, during the construction process, and well after the project is finished.

Pre-Construction Savings

Long before any work is done on-site, choosing precast concrete for your construction project can boost your bottom line. Pre-construction planning takes into account overhead costs, the design, and the all-important timeline. Working with precast concrete can help you save money in all of these areas.

>>Cut Overhead Costs

Precast concrete uses molds and forms to create different products necessary to achieve a total precast building system. For example, the ATMI Precast plant houses 20 production tables for manufacturing of precast beams, double TT’s, insulated or solid precast wall panels, columns, slabs, and more. These molds and forms can be recycled and re-used many times – therefore cutting overhead costs and saving you money. On the other hand, on-site concrete construction requires forms to be built from scratch for each project.

>>Stay Within Design Budgets

Precast concrete provides a variety of color, textures, and finishes, meaning it can serve as an affordable alternative to more expensive stone, masonry or tile. In fact, ATMI Precast can provide creative solutions such as inset brick and the use of liners to simulate natural stones.

Additionally, the molds can include design elements that can enhance appearance and presentation in your construction project. Keeping the design budget in check while still achieving your desired look and feel is key.

>>Reduce Weather Delays

Using precast concrete for your project means that you can get started right away. Not only can multiple project components get done at once, but the indoor, controlled environment means that your precast construction will stay on schedule, regardless of what Mother Nature has in store. This means, your project will get the green light no matter the time of year – because after all, time is money.

Construction Savings

When it’s time to get on-site and start building, you can count on precast concrete to cut your costs yet again. Using precast means that you can reduce your transportation and labor costs, minimize risk to your on-site workers, and forge ahead with a quality product that won’t let you down.

>>Slash Transportation Costs

Due to the fact that precast concrete products are constructed at one location and then transported on-site when ready, your general contractor doesn’t have to worry about multiple trade transports, making the operation cleaner and more efficient. Less workers, less equipment and less vehicles equates to less headaches and less expenses.

>>Minimize On-Site Accidents & Exposure

We know that the safety of your construction site is always a priority. One of the benefits of working with precast concrete and its off-site casting, which eliminates the need for other trades to work erecting structural frame. Furthermore, when working with precast, the dust exposure is limited almost exclusively to within the precast plant. A safe working environment is not only best practice, but it reduces any Workers’ Compensation costs as well.

>>Depend on Quality

Working with a reputable precast manufacturer means you have partnered with a company that commits to meeting high standards and delivers a quality product that you can rely on during the construction process. For example, ATMI Precast is certified through the Precast Concrete Institute (PCI). Working with ATMI ensures a high-quality precast product.

Post-Construction Savings

When your project is complete it’s out of your hands. But, in order to attract tenants, you have to be able to sell the features of your building. Of course, these plans may have been made in the pre-construction phase if you are building a facility for a specific occupant or use. Either way, these post-construction savings are what people are looking for.

               >>Save on Maintenance

Concrete is a hard and highly-durable material that is resistant to wear, weather, and damage. Sustainability is evidenced by precast concrete’s ability to facilitate LEED Certification. The investment value of a building increases if the structure lasts longer than expected. Furthermore, exterior precast concrete can be left untreated without damage from the elements. And, if painted, repainting is necessary only every five to ten years.

               >>Reduce Energy Costs

Precast concrete is highly energy efficient as concrete intrinsically retains heated or cooled air. This saves money on energy bills and reduces the overall energy load of the building. This is an important asset for designers who need to cut heating and air conditioning costs associated with HVAC systems – and it is an important selling point for precast concrete products.

               >>Be a Friend to the Environment

Precast concrete is completely recyclable, making it an environmentally-friendly choice. Concrete consists of water, sand, gravel and cement. To make the cement, gypsum is added to limestone, clay, sand and iron ore and the mixture is finely ground. This means that precast as a construction material is clean and waste-free, and the addition of by-products reduces requirement for cement in the mix.

Precast concrete provides unique benefits that can be found with no other material because it is naturally based and offers exceptional building aesthetics. Together with structural ability, speed, and economy, precast building construction is an unparalleled choice to get the most out of your project.

If there’s anything we can rely on in the Midwest, it’s that January and February (and sometimes March and April) will bring snow and extreme cold at times. This is usually a roadblock when it comes to construction – but not when it comes to precast concrete. Being able to build during the winter months is a huge benefit to working with precast concrete. Let’s explore how working with precast concrete can help you stay on time and on budget during the winter season.

The Problem: It’s definitely too cold for cast-in-place (CIP) concrete to set.

We talk about extreme cold as being an issue when it comes to setting concrete onsite. However, when the mercury drops below freezing temperatures, CIP concrete isn’t a viable option. In the Midwest region the temperature can get to below freezing as early as November or December. Of course, those temperatures can always stick around until May – it just depends on the year. That means that the “cold weather” season here can technically last as long as 7 months. The solution is building with precast concrete. Since this material is manufactured off-site, in temperature-controlled manufacturing plants, it’s the key to keeping construction going during this time of year.

The Problem: It’s probably too cold for CIP concrete to set.

If you live and work in the Midwest you know that we can wake up with a frost and end up in shorts and t-shirts in the late afternoon. The spring and fall seasons are traditionally unpredictable here, and banking on the accuracy of weather forecasts isn’t what we’d call a guaranteed game plan. If the temperature is hovering around where you need it to be for your concrete products to set, it can be a gamble resulting in inconsistent finishes. But, working with precast concrete products mitigates that risk. Quality control of precast concrete products is ensured by an internal batch plant where the precise aggregate, powder, water and other additives are mixed at a consistent temperature – therefore resulting in a uniform product.

The Problem: It’s too cold to send multiple crews.

When site conditions are tight, it can be downright dangerous to have too many trades onsite during snow and ice events. Minimizing worker exposure to the elements during extreme weather conditions is important to everyone involved – especially contractors. Working with precast concrete eliminates the congestion of having too many workers at the job site, thereby increasing safety.

ATMI Precast has the ability to start the design process and manufacturing prior to beginning on-site activities. Additionally, our year-round unimpeded manufacturing and erection capabilities mean your precast construction will stay on schedule. We offer unmatched economy and speed to complete your project on budget and on time.

Here in the Midwest, summer is queen. Average highs around 80 degrees in the months of June, July and August are common. Of course, in the construction industry, summer is prime time. While we have a busy schedule year-round (thanks to our indoor, temperature-controlled precast concrete facility) many of our partners rely on ATMI Precast to meet their summer benchmarks. But it’s not all blue skies and sunshine. Sometimes Mother Nature throws us a curve ball – and we have to be prepared for it.

Precast Concrete Construction in the Heat

While temperatures in the Midwest average in the 80s during any given summer, this area is known for its mood swings – not to mention the humidity. When temperatures climb upwards toward 100° and the humidity level rises with it, safety measures become extremely important.

According to the Occupational Safety and Health Administration (OSHA), most heat-related job site deaths occur in the first three days of work, and half happen on the first day of extreme heat. Whether employees are working inside or outside, safety protocols like taking short, frequent breaks, staying hydrated, and wearing lightweight and loose-fitting clothing are key. While the safety of our ATMI Precast team is our number one priority – there’s a few other things to consider when working in extreme heat, like equipment.

Equipment can overheat in the summer just as easily as a person can. Regular checks to ensure proper coolant and oil levels are important. It’s also good practice to train operators to recognize extreme heat conditions and understand when to pull back, in order to prevent stressing your equipment.

Precast Concrete Construction in the Rain

A rain shower isn’t a deal breaker when it comes to summer construction. Like anything else, if you’re prepared for rain, operations can continue with a few modifications. Notably, the most important areas to consider are slip and fall prevention and proper use of equipment that requires electricity.

OSHA doesn’t set specific standards for working in the rain, but it does provide guidance for outdoor industries like construction. For instance, rain increases the dangers associated with using cranes, derricks, and hoists to move large objects on-site. If a construction site experiences heavy rain and wind, it could make those loads difficult to control.

When working in the rain, workers should don protective gear and visibility clothing that have a slip-proof grip. Electrical equipment should be halted and stored safely away from wet conditions – indoors if possible. When a crane is on-site, check the wire rope, chains and hook for any signs of damage. And never move or load over workers – a safety standard that should be practiced at all times, but is especially important in wet conditions.

Precast Concrete Construction in Inclement Weather

Sometimes that rain shower escalates into something bigger – a thunderstorm. It goes without saying that when severe weather rears its ugly head, all outdoor construction comes to a halt. Lightning is a serious occupational hazard for construction workers.

Supervisors and workers should keep themselves aware of the potential for severe weather – including lightning – via weather forecasts and tools. When lightning is detected, workers should immediately take cover and remain there until the threat no longer exists. That means that every worker on-site should know where shelter exists in case of emergency. If an enclosed building is not an option – taking shelter in a vehicle is next-best. It’s important to note that lightning can strike as far as 10 miles from rainfall. Once workers take shelter, they should remain there for at least 30 minutes after hearing the last thunder.

But thunder and lightning aren’t the only dangers Mother Nature can dish out. High winds rank right up there and should be treated with the same respect. The most common injuries associated with windy conditions include being hit by flying debris, eye injuries due to small particles or dust, and objects falling from high surfaces. Prevention is easy here – protect yourself with personal protective equipment and eliminate work all together if the conditions persist or become too difficult to manage.

Weather is a big factor when it comes to safely and effectively getting the job done. Preplanning, keeping an eye on conditions and using common sense when it comes to knowing when to take shelter are important pieces of any construction plan.

For ATMI Precast, it is that time of year when cold weather plays an immense role in the procedures, requirements, and practices that encompass concrete production. Winter conditions present a huge challenge for the construction industry. Pouring concrete is difficult when temperatures drop to near freezing. Placing concrete in cold weather can be impossible once frost sets in unless you take a lot of precautions. Frigid winter conditions not only raise construction costs significantly, but they also slow schedules and reduce worker safety.

Being in the Midwest we are affected by winter weather, yet construction projects can continue year-round. That’s because many architects, engineers, and builders know that cold weather construction can easily be completed on time, within budget, and safely by using precast concrete in winter months. Precast concrete makes it possible to complete construction projects even during the extreme weather that comes in cold winter months. Cold weather practices need to be addressed for precast manufacturers, like ourselves, to product quality products that meet specifications.

Depending on the year, we can be affected by cold weather conditions in calendar months from October through April. That is over half the year where construction projects could be delayed or halted due to frost, ice, snow, or chilling winds. Builders plan for this and look for subcontractors like us to provide precast concrete solutions.

Concrete has helped build ever imaginable structure from skyscrapers to bridges and roads. But for all its benefits, it does have downsides. It cannot properly cure when it is too cold when poured outdoors. That is quite the restriction for on-site concrete pours. With concrete projects that are cast-in-place, forms are set, and concrete is mixed on the job site or trucked in from ready-mix plants.

Low temperatures cause concrete that is curing to go inert or stop setting. Freezing during the initial cure before it reaches 5,000 psi compressive strength will cause curing concrete to fail entirely. Either way, casting concrete outside of its temperature tolerance can be a financial disaster.

Luckily, ATMI Precast provides the perfect remedy to eliminating all the problems associated with cold weather pours which is precast. Precast concrete components are carefully constructed inside factory-controlled environments that remove all the risks. This results in regulated units that meet high standards in quality, strength, and design. No matter what the weather condition is outside.

There are many benefits of using precast concrete. The first is that it is designed by knowledgeable engineers. The engineers have had years of training and hands-on experience in casting all types of structural concrete. They work with the architect, project engineer, and construction manager to make sure the right concrete mixtures and additives go into the precast pour.

The second is factory conditions. This means that temperatures are artificially controlled to ensure optimum conditions exist when a component is cast. All concrete casting and curing are done in these conditions which eliminates volatile job variables like unexpected weather drops when a pour has been scheduled and must proceed. This will also save time on the job site. While bad weather can stall cast-in-place projects, this is not a factor for precast as we arrive ready to erect.

The third is quality control. Precast concrete is produced in an environment that allows for superior consistency and quality control. This is ensured by an internal batch plant where the precise aggregate, powder, water, and other additives are mixed at a consistent temperature. There is no guesswork or taking a chance. Consistent labor force daily contributes to the repeatable quality of our precast concrete.

The fourth is strength and durability. Precast concrete provides a long-lasting solution as it grows stronger over time. While other materials deteriorate, studies have shown that precast concrete can provide a service life of more than one hundred (100) years, requiring little or no maintenance.

Lastly, concrete is environmentally friendly which is extremely important in an increasingly eco-conscious world. After water, concrete is the most frequently used material on earth. Made of all-natural materials, it is safe for the environment and can be recycled. Concrete can also incorporate recycled materials.

By choosing precast concrete, you will keep your next project on budget and on time even in those winter months.

Did you know that concrete consists of five (5) components? These include cementitious material, large aggregate, small aggregate, water, and admixtures.

At ATMI Precast, we use multiple different cements, aggregates, and admixtures to produce concrete that benefits the safety, quality, and cost of our product that is outlined below.

Cementitious Materials:

• Type IL Cement
  • Blended cement that contains 5% – 15% limestone
  • Reduces the carbon footprint
  • More cost effective
• Type III Cement
  • Ground finer than Type I
  • Achieves high early concrete strength
• Slag
  • Improves workability
  • Easier to finish
  • Higher long-term compressive strength
• White Cement
  • Used for architectural finishes

Aggregates:

• 3/4″ Limestone
  • Typical large aggregate
• 3/8″ Limestone
  • Large aggregate used for architectural mixes
  • Used to increase flowability with a self-consolidating concrete
• Mason Sand
  • Small aggregate
  • Finer ground sand used for architectural mixes
• Torpedo Sand
  • Small aggregate
  • Typical sand used for both structural and architectural mixes
• Screenings Sand
  • Small aggregate
  • Crushed limestone used for architectural mixes

Admixtures:

• Superplasticizer or High Range Water Reducer
  • Simulates water in the mix to reduce the amount of water needed
  • Less water = higher concrete strength
• Viscosity Modifier
  • Prevents the mix from segregating
  • Suspends the aggregate in the concrete matrix
• Entrained Air
  • Adds micro air pockets to the mix to combat the freeze thaw in the Midwest region
• Retarder
  • Slows down the initial set of the concrete to allow for longer workability