CarbonCast High Performance Insulated Wall Panels provide structure and cost savings
- Project ProLogis Exit 8A Distribution Center, Building 11
- Location South Brunswick, New Jersey
- Type of Precast CarbonCast High Performance Insulated Wall Panels
- Project Size 751,000 sq. ft.
- CarbonCast Surface Area 159,000 sq. ft.
- Architect Arco Design Build
- Contractor Greenfield Builders, Inc.
- Construction Manager Greenfield Builders, Inc.
- Precaster Oldcastle Precast Building Systems
Builders of a 751,000-sq.-ft. ProLogis distribution center in South Brunswick, N.J., saved on superstructure costs by use of fully composite, load-bearing CarbonCast® High Performance Insulated Wall Panels from AltusGroup member, Oldcastle Precast Building Systems.
The wall panels feature C-GRID® carbon fiber shear trusses to connect each panel’s 3-inch thick interior and exterior wythes. The wythes encase four inches of continuous EPS insulation. The resulting 10-inch thick panel functions as if it were composed entirely of solid concrete. The 46-foot high CarbonCast panels support the warehouse’s roof load and eliminate the need for perimeter columns.
Further cost savings will be realized in heating and cooling. With the integral insulation, the CarbonCast High Performance Insulated Wall Panels were able to achieve a solid state R-value of R-18. Meanwhile, the C-GRID shear grid has relatively low thermal conductivity. It prevents thermal transfer between the wythes, virtually eradicating hot and cold spots on the interior wall. With thermally efficient wall panels, the building will be much slower to cool down and warm up, resulting in energy savings.
Over 350 precast elements were fabricated nearby and delivered for immediate erection, eliminating concern for weather delays or other setbacks while both keeping the project on time and within budget. The architect worked closely with Oldcastle to reuse the precast wall sections. A limited number of molds were used repeatedly to realize efficiency of scale. Panels incorporated 75 dock doors on two sides of the building and 50 knockout panels. Four overhead door openings were also included above a large glass entryway.
As with all precast, the CarbonCast panels went up quickly at a speed unachievable with tilt-up or other construction methods. The panels were finished with contrasting grey and navy blue paint.