Opi Residential Manual

7/30/2019 Opi Residential Manual

1/79

OLDCASTLE

RESIDENTIAL BUILDING SYSTEM

EQUUS DESIGN GROUPARCHITECTS PLANNERS


2/79

TABLE OF CONTENTS

USE OF THI S MANUAL

This Oldcastle Residential Building System manual has been de-signed to assist Owners, Architects, Engineers, and others in-terested in the use of precast concrete building systems for resi-dential buildings. Use of the information in this manual will behelpful as references for the design of multi-family residences,college residence halls and senior residence buildings; however,every project must be designed to meet local site conditionsand other local requirements.

The drawings and other information contained herein are illus-trative only and neither Equus Design Group, Inc. nor OldcastlePrecast, Inc. makes any representations as to their fitness forany specific design or structure, and disclaim any responsibilityfor techniques of application, correctness, interpretations, de-sign methods, modifications or misapplications of these draw-ings and references.

Since no specific project nor overall engineering responsibility isimplied with the use of this manual and the information con-tained within, neither Equus Design Group, Inc. nor OldcastlePrecast, Inc. will be responsible for the failure of any designer to

properly design nor any contractor to properly construct anybuilding.

For more information, visit us at www.oldcastlesystems.com

Introduction to Oldcastle Precast

Residential Planning Principles

Oldcastle Residential BuildingSystem

Architectural & Structural Details Sustainable Design

Case Studies

References & Resources


3/79

THE OLDCASTLE RESIDENTIAL SYSTEMPrecast Building Systems for the 21st Century

A Bu i ld in g Syst em ... Fr om a Sin g le Pr ov ider ... Par t ner in g w it h Cl ien t s...

The Oldcastle Residential Building System is morethan just a kit of precast concrete parts. It is a

method for architects and owners to employ forthe total design and construction of residentialbuildings. It is a system designed for wideapplication in residential markets - multi-familyresidences, college dormitories and seniorresidences.

Oldcastle uses a cooperative team methodology. Ourstaff works closely with owners and architects

throughout the design and building constructionprocess providing expert engineering and technicaladvice and support. Oldcastle Precast BuildingSystems is part of the largest precast concretemanufacturer in the United States. We specializein TOTAL BUILDING SYSTEMS by providing design,pre-fabrication and erection services for wholeresidential buildings. Having a single sourceresponsible for the entire building superstructureand envelope allows owners and architects to makethe changes or adapt the design with less risk, fewer

coordination issues and less site mobilization, whilekeeping costs under control.

Oldcastle works directly with Owners and Architectsfrom project inception and each step of the way

from the initial design to construction completion.Through direct partnerships, Oldcastle representa-tives are able to offer creative methods to saveowners and contractors time and money, and toassist architects and engineers during the designprocess.


4/79

Colleges and universities respond to the housingneeds of different age groups and diverse multi-cultural and economic backgrounds of theirstudents. Similarly, the Oldcastle ResidentialBuilding System is adaptable to a wide variety ofResidence Hall types - dormitories, suites,apartments, studio, and couples housing. The

system can be customized in appearance to suitthe architectural context of various campuses.

Col lege Residen ce Hal ls Sen ior Liv in g ResidencesMult i -Family Residences

The Oldcastle Residential Building System isdesigned for a wide variety of multi-family housingtypes low and row housing, mid-rise and high-rise buildings, and low-income to luxury units.Furthermore, the system can be utilized for moststyles of living standard unit layouts, loft styleunits, skip-stop elevator buildings, terraced

buildings, and contemporary and traditional styles.

The increasing numbers of older people, with theirexpectations for a high quality of life, is creatingthe need for new care and housing options. Therehas been a surge in design of a wide variety ofchoices including long term care, assisted living,communities for active lifestyles, independent livingfacilities, and special needs for dementia and

continuing care. The Oldcastle Residential BuildingSystem is adaptable to meet the needs of mostsenior living lifestyles and designs.

1 2 3


5/79


6/79


7/79


8/79

RESIDENTIALPLANNING PRINCIPLES


9/79

RP.1 Low, Mid & High RiseRP.2 Residential FormsRP.3 Forms in SectionRP.4 Multi-Family ResidentialRP.7 Residence HallsRP.10 Senior ResidencesRP.13 Mixed-Use

RESIDENTIAL

PLANNING PRINCIPLES


10/79

Mid-rise buildings, 4 to 8 stories tall with elevators,are the most common style of multi-family housing.The mid-rise is typically a low, broad, horizontalbuilding in suburban settings.

Mid-Rise High -RiseRow / Lo w -Rise

Low-rise buildings, from 1 to 3 stories high, aretypically found in residential neighborhoods andquiet urban streets, often with no elevator. Buildingtypes include rowhouses, townhouses and studios.

The high-rise, 9 stories and higher, is typically talland narrow, located in downtown, urban settingswhere land and parking are a premium. Often theyare mixed-use occupancies with parking or retail atthe lower levels.


11/79

RESI DENTI AL FORMS

Most residential buildings are organized in commonrecognizable forms. The form of the building(s) isusually determined after the Owner and Architecthave determined the program components anddesired relationships, performed a site and zoninganalysis, and determined the appropriateconstruction type.

The Oldcastle Residential Building System isadaptable to a wide variety of orthogonal or planarforms similar to those illustrated in this section.

The array of form possibilities with a total precastbuilding system provides the owner and architectwith nearly limitless creative opportunities.

STEPPED PLAN FLAT FACADE CRENELLATI ONS PROJECTI ONS I NSERTI ONS

OPEN COURTYARD ROW GALLERY PARALLEL FORMS COLLECTED FORMS

ENCLOSED COURTYARD CROSS CORE CENTRAL CORE

CORNER OFFSET LI NEAR


12/79

LOW -RI SE MI D- RI SE HI GH- RI SE

SKI P-STOPSTEPPED

Low r ise housing (1-3 stories) is often designedas row-houses, with interior stair circulation withinor between units.

Mid- r i se (4-8 stories) and High- r i se (9+ stories)buildings are typically double or single loadedcorridor types serviced by elevators. The double-loaded corridor gives the exterior walls of thebuilding to the units to maximize views and sunlight.The single-loaded ga l le ry corridor places units onone side of the building and is generally for sites

with limited width or particularly desirable views.

Sk ip -s top plans locate a corridor on every secondor fourth floor. The units are typically two stories.Unit entry is from a corridor and an internal stairconnects the floors of the unit.

Advantages of skip-stop include:

potential for cross-ventilation with views andsun exposure on two sides of the building

ability to create two-story high loft type space

less underutilized corridor space

The s tepped , or terraced, configurations are thosewhere the units open to an outdoor terrace spacetypically formed by the top of the unit below.

Advantages of stepped include:

improved views and privacy

ability to comply with zoning restricting building

heights at street or property lines ability to create parking or other non-residential

uses at inner levels where the footprint is larger

P a r k i n g below the living space can increasedesirability, reduce land acquisition, and help in tighturban locations.

GALLERY

COURTYARD FORM W/ PARKI NG

FORMS I N SECTI ON

PARKI NG BELOW


13/79

MULTI-FAMILY

RESIDENTIAL

The Oldcastle Residential Building System is designed toaccommodate the widest range of multi-family housingtypes possible. The fundamental character of the housingis defined by its scale.

High-Rise housing is generally found in urban settings,where high-density housing is allowed by local zoning or-dinances. However, it is also built in areas where the

high-rise configuration offers excellent views or allows thepreservation of significant open space that might other-wise be covered with lower scale housing.

Typical high-rise building configurations include a commonstreet level lobby leading to a central core with elevators,stairs and other vertical elements that serve a limitednumber of units. An increasing number of high-risehousing projects offer other mixed-uses such as retail,professional offices, and, often, below-grade parking.

Mid-Rise housing, as defined in this Manual, is in the 4 to8 stories height range. The buildings are generally broaderin width or length than in height, often covering a largeportion of a city block. The mid-rise requires elevatoraccess that is often placed at approximately the mid-pointof the building serving a double- or single-loaded corridorto the units. Egress stairs are typically located at eachend of the corridor.

Row or Low -R ise hous ing . The townhouse is a verycommon form of row house. Typically 2-4 stories tall, theessential characteristics of the townhouse are direct streetaccess to units or groups of units; both front and rearexposures; and shared common walls with adjacent units.Parking is typically on grade or at the street outside thetownhouse.


14/79

Oldcastle Residential Building Systems arecapable of providing total precast structuralsystems for buildings up to 18 stories andhigher.

CENTRAL CORE LAYOUTS

SI NGLE-LOADED CORRI DOR LAYOUT

DOUBLE-LOADED CORRI DOR LAYOUT

TYPI CAL SECTI ON

Multi-family housing in high-rise buildings typically has acentral core with elevators, stairs and other buiding services.

The single loaded corridor, or gallery, is generally used to maximize bestview potential, for narrow lots, or to back-up to other buildings or uses.

The double-loaded corridor is the most efficient form of circulation inmulti-family housing. It can be used for low-, mid-, or high-rise buildings.


15/79

Precast concrete plank, with the ability to free spanover 50 feet, can greatly reduce a buildings floor-to-floor height over other structural systems suchas steel frame. The result is a reduction in theoverall building height and the elimination of excessbuilding material and cost.

Typical Section

Typical Row House

Typica l Mul t i -Fam i ly Uni t Layout s

Unit layouts are typically dependent on the overall

building layout. Buildings with long corridorsnormally have units with the main living areas andbedrooms having direct access to outside light, thusrequiring these rooms to be along an exterior wall.

Service areas such as the kitchen, bathrooms,laundry and closets that do not require exterior lightare normally placed along the interior corridor wall.

STUDI O 1 BR 2 BR 3 BR

BALCONYBAY PROJECTI ON

BASEMENT 1 ST LEVEL 2 ND LEVEL 3 RD LEVEL

Row houses and townhouses areideal building types for theOldcastle Residential BuildingSystem. Each unit can becompartmentalized with sound

deadening precast concrete panelsand, with the use of precast plank,the floor layouts are virtuallylimitless. By enclosing the frontand rear with precast panels theend result is a quiet, energysaving, environmentally friendlyresidence that requires little or nomaintenance.


16/79

RESIDENCE HALLS

The Oldcastle Residential Building System provides safe,secure, energy efficient, and low maintenance ResidenceHal ls and D or m i t o r i es for colleges and universities.

Fitting within the architectural character of campuses isgenerally a crucial factor in the design of residence halls.Often the need is for buildings with specific styles andmaterials. Oldcastles system of precast componentsincludes variations on materials such as brick and otherfacings to complement the most demanding conditions.

At the same time, the style of living units has evolved inrecent years to more than the single or double occupancyrooms with common shower areas. The diverse nature ofstudent populations places demands on colleges anduniversities to respond with appropriate housing types.

Dorm i to r ies , Su i tes , Stud ios , Apar t men ts , Coup les ,and F a c u l t y housing types each have differentcharacteristics; and an increasing number of institutionsare providing them to attract the best students and faculty.

This section of the manual illustrates various types ofbuilding and living unit configurations, leaving only theimaginations of the architect and owner to explore ideasto suit their specific requirements.


17/79

SUI TES I NDOUBLE LOADED CORRI DOR

Common floor plan arrangements for collegeresidence halls often include centralized corefunctions with stairs, elevator, common parlor,bathrooms and showers as well as conferencerooms, study areas, kitchenettes and dining areas.

Living units range from single or double occupancyrooms to suites and apartment layouts along acentral corridor.

Corridor and living unit walls made of concretepanels can be provided with a smooth form finishand a trowel finish, ready for painting; thiseliminates the need for some interior drywallpartitions, greatly reduc ing r oom dam age andm a i n t enanc e issues.

RESI DENCE HA LLBUI LDI NG LAYOUTS

CENTRAL CORE W I THDOUBLE-LOADED CORRI DOR

CENTRAL CORE CORNER CORE


18/79

The types of living arrangements in residence hallsvary depending upon the philosophy of collegeadministrators. Modern trends are for single anddouble-occupancy rooms for undergraduatestudents, while suites and apartment style unitsappeal to older undergraduate and graduatestudents seeking to live with a specific group ofpeople in a more normal residential environment.

Housing for younger undergraduates usuallyconsists of single or double occupancy sleepingrooms arranged along a common corridor andsharing common toilet and bathrooms.

Suite housing combines multiple single or doubleoccupancy sleeping rooms, typically two to six, witha shared living area and bathrooms. Suites areself-contained private living areas, and like standardundergraduate housing, do not have kitchens.

Apartment style housing is similar to suite housingwith the addition of a kitchen and possibly privatebathrooms.

DOUBLE OCCUPAN CY ROOMS

I N SUI TE STYLE LAYOUT

RESI DENCE HA LLUNI T LAYOUTS

SI NGLEOCCUPANCY

DOUBLEOCCUPANCY

DOUBLEOCCUPANCY

DOUBLE OCCUPAN CY ROOMSI N APARTMENT STYLE LAYOUT

SI NGLE OCCUPAN CY ROOMSI N APARTMENT STYLE LAYOUT

SI NGLE AND DOUBLE OCCUPANCY ROOMS

I N APARTMENT STYLE LAYOUT


19/79

SENIOR RESIDENCES

The baby-boom generation of over-65 seniors is the mostrapidly growing population segment in the United States.The housing industry, in both the private and public sectors,is faced with the challenge of meeting the housing andcare needs of this highly diverse group of society.

The Oldcastle Residential Building System is capable ofproviding housing and service needs to the widest rangeof Sen i o r R esi denc e Bu i l d i ng T y pes, including thefollowing:

I ndependen t R esi den t i a l Apa r t m en t sGenerally for the active over-55 age population, this ishousing for people with limited care needs.

Cont in u ing Care Ret i rem ent Com mu ni t iesCCRCs are a model of living that provides services andcare for a wide variety of needs ranging from independentliving to more focused and specialized health care needsof assisted living and long-term care residents.

Ass is ted L iv ing Res idenceHousing for individuals unable to live on their own but notneeding the high level of care required in a long-termcare residence.

Long Term Care Res idenceFacilities for residents needing a high degree of servicesand care such as Alzheimers Care, Hospice Care,

Rehabilitation and Nursing Homes.


20/79

SENI OR RESI DENCEBUI LDI NG LAYOUTS

Building layouts of senior residences vary dependingon a multitude of factors site size andconfiguration, lifestyle and program requirements,and owner and architect preferences. Some

common layouts are shown here.

There are many lifestyle options available forseniors. They can range from independent livingto assisted living and continuing care communities.

Each one is programmed and designed by ownersand architects to meet the lifestyle and health carerequirement of the residents.

I ndependent L iv ing Res idences provide a placefor seniors to live within a community of others theirage, with little to no health care support.

As s i s t ed L i v i ng R es i denc es provide varyingsupport services based on the changing needs ofthe residents. Typically they are for those who are

unable to live safely on their own, but who do notrequire a high level of health care support.

Cont inu ing Care Ret i rement Comm uni t ies offerhousing for seniors requiring a full compliment ofsupport services such as dining, housekeeping,health care, and access to social activities.

DOUBLE-LOADED CORRI DORDOUBLE WI NGS

CENTRAL COURTYARD


21/79

MULTI -BEDROOM SUI TE

2 BR APARTMENT

SMALL 1 BRSTUDI OSLEEPER

SENI OR RESI DENCEUNI T LAYOUTS

2 BR SUI TE

LARGE 1 BR APARTMENT

Developers of senior living facilities, and theirarchitects, create programs and designs to suitspecific market targets. The design of eachindividual living unit is at the heart of their decision-making process.

Senior residence living unit designs vary greatlydepending on the health, well-being and lifestyleof the individuals. Seniors still living active,

independent lifestyles generally seek the type ofliving arrangement that reflects their independence full kitchens, large furnishable living rooms andbedrooms, and adequate storage. On the otherhand, some seniors, particularly those with lifechanging conditions such as dementia orAlzheimers, may be better served with smallerunits, or shared suite arrangements, that arecomplemented with an array of beneficial servicesand activities in the building.

This page shows several of the plan layouts for livingunits that are commonly used in senior residences.Often the development, particularly in ContinuingCare Retirement Communities and Assisted LivingFacilities, will have a wide mix of living unitarrangements to suit the needs of a diverse seniorpopulation.

Reaching an understanding of the living unit mixand design requirements in a project helps

considerably in the planning and design of thebuilding layout and characteristics of the appropriatesuperstructure. Oldcastle representatives can assistowners and architects in the early programmingand planning phases of the project to identify cost

effective solutions for each condition.


22/79

MIXED-USE

Owners and architects are often faced with the challengeof providing more than one use in a development, often ina single building.

Where a mix of different uses is required in the building, itis important at the outset of design to gain anunderstanding of a design module that can suit each use.For example, the module of a parking garage - the carand the space it needs - is different for multi-familyhousing, hotel rooms and conference areas, professionaloffices, and retail space. Nevertheless, all of these different

uses could be combined into a single building.

The Oldcastle Residential Building System is specificallydesigned to create superstructure solutions thataccommodate varying conditions. It is important for theOldcastle representative to gain a clear understanding ofthe program and design parameters early in the processto maximize the potential for cost-effective solutions for

both the superstructure and building envelope.


23/79

OLDCASTLE RESIDENTIALBUILDING SYSTEM


24/79

BS.1 Architectural Principles ofConcrete Design

BS.2 Precast System ComponentsBS.3 Cross Wall SystemBS.4 Bearing Wall SystemBS.5 Wall PanelsBS.7 Floor and Roof PlankBS.8 Balconies

BS.9 StairsBS.10 ElevatorsBS.11 Facade Treatment OptionsBS.13 Concrete FinishesBS.14 Formliner FinishesBS.15 Embedded BrickBS.18 Brick FinishesBS.19 Other Trim Materials

OLDCASTLE

RESIDENTIAL

BUILDING SYSTEM


25/79


26/79

EXTERI OR I NSULATED ANDNON-I NSULATED LOAD BEARI NG PANELS

BEAMS

OLDCASTLE PRECASTSYSTEM COMPONENTS

COLUMNS

STAI RS AND

LANDI NGS

FORM LI NER

FINI SHES

REAL BRI CKFACI NG

DECORATI VECORNI CES

BALCONYSLABS

FLOOR ANDROOF PLANKS EXTERI OR NON-LOAD BEARI NG PANELS

I NTERIOR LOAD BEARI NGPANELS AND SHAFTS

I NTERI OR NON-LOADBEARING PARTI TI ONSAND SHAFTS

Oldcastle provides total precast concrete solutions forresidential buildings. From exterior walls with architecturalfinishes, to floor and roof structures, stairs and shafts,and the entire superstructure, the Oldcastle System ofcomponents is designed to accommodate the wide range

of residential building types and uses illustrated in thismanual.


27/79

CROSS WALL SYSTEM

SECTI ON

The Oldcastle Residential Cross Wall System is comprisedof load-bearing interior precast panels and floor and roofplanks. Columns and beams are used at parking levels.Non-load bearing exterior panels can enclose thesuperstructure, providing a total precast concrete buildingsystem.

Cross Wal l Advantages:

Ideally suited for residential

buildings with parking at lowerlevels

Lends itself well to the addition

of bays and balconies Allows for a high percentage

of non-load bearing exteriorpartitions

Creates the opportunity for

sound-deadening precast wallsbetween units

ROOF PLANK

NON-LOAD BEARI NGEXTERI OR WA LL

BALCONY SLAB

LOAD BEARI NGCROSS WALL

BEAMS &COLUMNS

BEAMS &COLUMNS

FLOOR PLANK

LOAD BEARI NGCROSS WALL

NON-LOAD BEARI NGEXTERI OR WALL

ROOF PLANK

FLOOR PLANK


28/79

SECTI ON

The Oldcastle Residential Bearing Wall System is comprisedof load bearing interior and exterior precast panels withfloor and roof plank, providing a total precast concretebuilding system.

Bear ing Wal l Advantages :

Maximizes the open areas of

building plans

Creates flexible options for

floor plan layouts

Creates a sound-deadeningprecast wall at the corridor

Least expensive total precast

solution

Building is enclosed as

structure is being erected

BEARI NG W ALL SYSTEM

FLOOR PLANK

LOAD BEARI NGEXTERI OR WALL

LOAD BEARI NGI NTERIOR WALL

ROOF PLANK

LOAD BEARI NGEXTERI OR WALL

ROOF PLANK

FLOOR PLANK

LOAD BEARI NGI NTERIOR WALL


29/79

12 MAX

40MAX

40 MAX

12MAX

W ALL PANELS

STANDARD PANEL I NSULATED PANEL

SPECI AL SHAPESVERTI CAL

HORI ZONTAL

Within the Oldcastle system of components, precast wallpanels are available in a wide variety of types,configurations and finishes. From interior load-bearingstructural panels to exterior, insulated, brick-embeddedarchitectural finish panels, the Oldcastle system is designedfor total precast solutions for residential buildings.

Typically, precast panels are cast on flat forming beds withincontrolled factory conditions. Depending on the desiredarchitectural effect, various formliner finishes or masonryfacing options are available.

Window and door openings are created by blockouts onthe forming bed, and rails are placed to form the panelperimeter. After reinforcement and lifting devices areplaced, the concrete is poured and cured. The panels are

then lifted by cranes and stored until delivery and erectionat the job site.

Standard wall panels are 6 to8-inches thick, depending onuse and function. Non-loadbearing conditions typicallyrequire no more than 6-inches, whereas load-bearingconditions usually require 8-inches.

Insulated wall panels consistof three wythes; a 2-3 inchconcrete exterior, 2-3 inchesof rigid insulation, and 2-8inch concrete interior.Insulated wall panels can beused in both non-load bearingand load-bearing conditions.

1


30/79


31/79


32/79

BALCONI ES

Oldcastle offers a variety of solutions for precastconcrete balconies and bays in both cantileveredand recessed applications. Wet cast slabs are thepreferred method, enabling proper pitch and drain-age. Consult with Oldcastle engineers for appro-

priate designs.


33/79

STAI RS

CODE CONSI DERATI ONSBeing an essential component in the circulation andegress systems of most buildings, stairway designis strictly controlled by building code regulations.The information contained here summarizes somecommon building code requirements for egresss t a i r w ay s. However, designers must always verifywith the latest national and local codes.

St a i r w ay W i d t h the minimum stairway widthshall not be less than 48 wide for enclosed exitstairways.

Risers and Treads - shall be of uniform size andshape. Risers shall be between 7 max. and 4 min.The tread depth shall be 11 min. The mostcommon rule for comfortable proportioning of stairsis: 2 x riser height + tread depth = 25 inches.

Land ings the width of landings shall not be less

than the width of the stairway they serve and arerequired at the top and bottom of stairs andintermediate points to ensure that no single flightof stairs has a rise greater than 12-0.

Handra i l s are required on both sides of stairsand may project into the required stairway widthno more than 4-1/2 on each side. They shall beuniform in height, located 34-38 above the stairtread nosing. Handrails must be continuous or theends must project beyond the top and bottom ofthe stairs and return to a wall or guard.

G u a r d r a i l s shall be no less than 42 high,measured vertically from the leading edge of treadand shall have balusters or ornamental patterns sothat a 4-inch diameter sphere can not pass through.

Roof Access buildings over four stories with aroof slope less than 4 in 12 require stair access tothe roof.

Stairway walls, floors, landings and steps are allprecast concrete components that can be providedas part of the Oldcastle Residential Building System.


34/79

ELEVATORS

ELEVATOR PLAN

The elevator system, consisting of the hoistway, machine

room, cab and lobbies, is an integral and complex system.Proper sizing, quantity and type of elevator depends onthe number of occupants, number of floors, floor heightsand other factors.

Oldcastle Precast has a complete line of concrete productsto meet the requirements of the elevator hoistway andpenthouse to complement and support the OldcastleResidential Building System.

An elevator representative and code official should beconsulted early in the design phase and during the selectionprocess to ensure that the most suitable elevator systemis chosen.

The two most common elevator systems are Hydraulicand Electric elevators.

Hydrau l i c E leva to rs

Hydraulic elevator systems come in two styles, holed and

holeless. Both use a pump near the base of the hoistwayto raise and lower the elevator cab using a plunger. Dueto restrictions in the plunger length and lower speeds,hydraulic elevators are limited to low- and mid-risebuildings of up to approximately 60 feet. They generallyrequire the least initial installation cost, but use more powerduring operation.

Elect r ic Elevators

Electrical elevators rely on an electric motor and drivesheave that raises and lowers the elevator cab by steelcables and a counterweight. The electric motor is locatedeither at the base or above the hoistway. Medium to highspeeds and almost limitless rise allow electric elevators toserve low- to mid- to high-rise buildings.

ELEVATOR SECTI ON


35/79


36/79


37/79

SAMPLE CONCRETE FI NI SHES

Oldcastle Precast offers a wide range of

precast concrete colors and textures. Thearchitect should contact the local Oldcastlerepresentative in the early design stages andthroughout the development of the design forinformation on how to best obtain the visualeffect desired.

Note:The images shown in this manual representmany of the available color and texture

blends. These samples serve only as a visualguide for initial selection of color and texture.It is important to note that the colors andtextures seen will vary depending on localconditions. Since it is impossible to reproduceexactly on paper the true colors of precastmix designs, some variations from thesesamples must be expected.

Additionally, due to different material sourcesor different techniques in various plants, the

architect should not expect to select aphotographic sample and obtain exactmatching by all precast concrete producers.Samples should be required to ensure thatthe desired colors and textures can besatisfactorily matched.

Photos courtesy of PCI

01 02 03 04

08070605

09 10 11 12

13 14 15 16 17 18


38/79

SAMPLE FORMLI NER FI NI SHES

Forml ine rs

Oldcastle offers owners and architects theoption to cast concrete in forms with specialtyformliners to create almost any desired visualeffect. In addition to a vast array of patternsand textures offered as standard, there is alsothe option to create custom formliner finishesin almost any style imaginable. Oldcastleworks directly with the nations premiermanufacturers of formliners including those

represented in the patterns shown on thesepages.

The images shown in this manual representmany of the textures and patterns available.The samples shown are only a visual guide forinitial concept, not for actual selection. TheOldcastle representative will make availablemore accurate literature and samples when

requested.

Mason r y St on e an d RockLow Pro f i l e


39/79

EMBEDDED BRI CK

COURSI NG OPTI ONS

CORE SAMPLE SHAPES AND SI ZES

FLEMI SH BOND HALF BOND STACKED BOND

BASKET W EAVE QUARTER BOND ROW LOCK BOND SOLDI ER BOND

RUNNI NG BOND

NO MORTAR

NO AI R SPACE

NO WEEP JOI NTS

NO LI NTELS

NO FLASHI NG

NO WATERPROOFI NG

NO EFFLORESCENCE

NO FREEZE/ THAW

NO DOVETAI L

ANCHORS

1

2

4

3

For owners and architects seeking brick finishes,Oldcastle offers thin brick which is integrally castinto concrete panels. A wide variety of sizes,shapes, colors and textures are offered, as well asa multitude of coursing options. Advantages of

brick-embedded concrete include no flashing, lintelsor weep cavities, no efflorescence and no time-consuming site construction or masonry products.


40/79

EMBEDDED BRI CK OPENI NGS


41/79

BRI CK AND CONCRETE FRAMESBRI CK FRAME

For an all-brick facade appearance, brick returnscan be applied at jambs, sills and heads. Carefulplanning of window sizes is required if minimizingthe cutting of bricks is a goal. At sills, a sloping sillextender is required from the window manufacturerto fully cover any flat brick surface.

TYPI CAL OPENI NG DETAI LS

CONCRETE FRAME

For the traditional appearance of stone sills andheads, concrete can be formed either flush with orprotruding from the brick facade. Brick returns aretypically applied at the jambs.

The most cost-effective opening is formed withconcrete at the jambs, sill and head. This reducesthe amount of brick cutting and allows for flexibilityof window sizes as the openings are determined bythe concrete, not brick coursing. The concrete framecan be flush with the facade or protruding.

2

4

5

1 2 3 4 5 6

2

4

6

1

3

5

flush or protruding flush or protruding flush or protruding


42/79

SAMPLE BRI CK FI NI SHES

Thin Br ick

Oldcastle offers owners and architects theoption to integrally cast brick in concrete. Fromthe nations premier manufacturers of thinbrick, there is a wide array of brick optionsavailable. The images shown in this manualrepresent many of the available color andtexture blends. Brick corners and edge capsare also available. Furthermore, flashed blendssuch as light, dark, and vintage flash and mixed

blends are available by custom order inminimum quantity orders.

Advantages of brick-embedded concreteinclude no flashing, lintels or weep cavities;no efflorescence; and reduced constructiontime.

Thin brick may vary in size and shade fromrun to run and within each run. Bricks shouldbe blended from numerous cartons on the jobsite. The color samples shown here are only a

visual guide for initial concept, not for actualselection. The Oldcastle representative willmake available more accurate color literatureand samples when requested.


43/79

OTHER TRI M MATERI ALS

Oldcastle assists designers and owners in the coordinationand design of its precast products with various exteriortrim materials such as composites, metal, wood, terracotta, ceramics, masonry, EIFS, and fiberglass.


44/79

ARCHITECTURAL &

STRUCTURAL DETAILS


45/79

USE OF THESE DETAI LS

The drawings and other information contained herein are illus-trative only and neither Equus Design Group, Inc. nor OldcastlePrecast, Inc. makes any representations as to their fitness forany specific design or structure, and disclaim any responsibilityfor techniques of application, correctness, interpretations, de-sign methods, modifications or misapplications of these drawingsand references.

Since no specific project nor overall engineering responsibility isimplied with the use of this manual and the information con-tained within, neither Equus Design Group, Inc. nor OldcastlePrecast, Inc. will be responsible for the failure of any designer toproperly design nor any contractor to properly construct anybuilding.

ARCHITECTURAL DETAILS

INSULATED LOAD-BEARING PANEL DETAIL2

NON-INSULATED PANEL-TO-FOUNDATION DETAIL4

BELOW-GRADE PARKING FOUNDATION DETAIL3

NON-INSULATED LOAD-BEARING PANEL DETAIL1

INSULATED PANEL-TO-FOUNDATION DETAIL5


46/79


PRECAST PARAPET DETAIL2

TYPICAL COPING DETAIL AT ROOF4

INTERIOR PANEL-TO-PANEL DETAIL3TYPICAL COPING DETAIL AT PARAPET1

INSULATED PANEL WITH PARAPET DETAIL5 INTERIOR PANEL-TO-FOUNDATION DETAIL6


47/79


BUTT CORNER JOINT DETAIL2

PRECAST CONCRETE BEAM SECTION4

BRICK CORNER JOINT DETAIL3MITERED CORNER JOINT DETAIL1

WINDOW SILL DETAIL - NON-INSULATED PANEL5 WINDOW SILL DETAIL - INSULATED PANEL6


48/79

STRUCTURAL DETAILS

USE OF THESE DETAI LS

These details represent a sampling of typical Oldcastle BuildingSystem details for various building conditions. Please consultan Oldcastle representative for specific details for each project.

The drawings and other information contained herein are illus-trative only and neither Equus Design Group, Inc. nor OldcastlePrecast, Inc. makes any representations as to their fitness forany specific design or structure, and disclaim any responsibilityfor techniques of application, correctness, interpretations, de-sign methods, modifications or misapplications of these draw-ings and references.

Since no specific project nor overall engineering responsibility isimplied with the use of this manual and the information con-tained within, neither Equus Design Group, Inc. nor OldcastlePrecast, Inc. will be responsible for the failure of any designer toproperly design nor any contractor to properly construct anybuilding.

EXTERIOR WALL AT FOUNDATION5

PLANK SIDE CONNECTION AT EXTERIOR WALL3PLANK END BEARING AT

EXTERIOR INSULATED WALL1 PLANK END BEARING AT EXTERIOR WALL2

EXTERIOR INSULATED WALL

AT FOUNDATION

4


49/79

STRUCTURAL DETAILS

INTERIOR WALL AT FOOTING5PRECAST COLUMN AT FOOTING4

PRECAST CONCRETE BEAM SECTION1

PLANK BEARING AND SECTION AT

CORRIDORS AND LARGE OPENINGS6

PLANK END BEARING AT INTERIOR WALL2 PLANK END BEARING AT EXPANSION JOINT3


50/79

STRUCTURAL DETAILS

INTERIOR WALL PANEL JOINT6

ROOF PLANK BEARING AT EXTERIOR WALL1

( PLAN VI EW) ( PLAN VI EW)

( PLAN VI EW) ( PLAN VI EW)

ROOF PLANK BEARING AT INTERIOR WALL4

INSIDE WELD PLATE CONNECTION

AT CORNER WALL PANELS2 OUTSIDE WELD PLATE CONNECTION

AT CORNER WALL PANELS3

WALL PANEL BUTT JOINT

WITH HIDDEN CONNECTION5


51/79

SUSTAINABLE DESIGN


52/79


53/79


54/79


55/79


56/79

CASE STUDIES

CASE STUDIES


57/79

1

3

2

5

The Juliana Lincoln University

Melrose II University of Delaware4Scranton University

THE JULIANA


58/79

Hoboken, New Jersey

Pro jec t Descr ip t i on - 128-unit luxury livingcomplex comprised of two four-story buildings withcovered first level parking, bay window projectionsand courtyard, totaling over 201,000 SF.

II. Pro ject Team -Owner:

Kawoz LLC, Hoboken, NJGeneral Contractor:

Ashley REMI Inc., Hoboken, NJArchitects:

Equus Design Group, Inc, Belmont, MA(precast concrete design architects)Bodnar Architects & Assoc. Long Valley, NJ(local architect-of-record)

Precaster and Precast Specialty Engineers:Oldcastle Precast Building Systems Division

III.

I.

Majo r Fea tu res -Total Precast Building System:

Exterior Load and Non-Load Bearing Panels

Interior Load Bearing Cross Wall Panels

Hollow Core Floor and Roof Planks

Special Bay Window Floor Projection Slabs

Beams and Columns at Parking Level

Stairs and Landings - Interior and Exterior

Elevator and Stair Shaft Walls

Special Arch, Pediment, and Curved Panels

Embedded Brick Finish (9 colors)Formliner Finish (stone)Composite Cornice and Trim1,624 Precast Pieces

696 8-foot wide planks72 columns40 beams244 7- and 8-inch interior wall panels48 stairs48 landings408 exterior wall panels

THE JULI ANA


59/79

Three levels of living units above oneenclosed garage in two separatebuildings

Exterior wall panel being poured inthe plant

Metal clad bay window projectionsin rhythm with embedded thin brickprecast panels

Precast panels and stairs used tocreate 2nd level entries

Exterior wall panel being erected atthe 2nd level

Exterior facade with compositewindow header and cornice, andmetal clad bay window

Concrete floor projections at baywindows

Acid etched precast panels withstone-like formliner finish at base ofbuilding

View from street showing stair to liv-ing units, bay projections, thin brick

and composite headers over precastframed window openings

End view of both buildings at sidestreet 1st level garage entries

Courtyard view between both build-ings showing a variety of different

thin brick colors

Ornamental bracketed compositecornices atop the precast panels

1 2 3 4

5 6 7 8

9 10 11 12


60/79

ORIGI NAL FLOOR LAYOUT ( TYPI CAL)

MODI FI ED FLOOR LAYOUT ( TYPI CAL)

PRECAST FLOOR LAYOUT ( TYPI CAL)

The original design of the Juliana project was load bearing metal stud construction witha brick exterior cavity wall and concrete floor and roof plank.

Oldcastle was able to implement the total precast Cross Wall Building System with onlyslight modifications to the unit arrangement and minimal changes to unit layouts, unitcounts, and exterior appearance, greatly simplifying the structural system of the project.

1

2

Precast floor plank span and bear on the interior precast cross walls and end walls ofthe building. A steel lintel is used between the cross walls at the corridor location.

3


61/79

PARTI AL MODI FI ED FLOOR LAYOUT

PARTI AL PARKI NG GARAGE LAYOUT

Parking layouts are easily adaptable to the Oldcastle Cross Wall Building System. With theuse of columns and beams to carry the load of the Cross Walls above, and the Drop-Beam

sytem for running utilities, there is ample space to provide safe and secure parking on thefirst level, protected from the weather.

1

2


62/79

ORI GI NAL FRONT ELEVATI ON

MODI FI ED FRONT ELEVATI ON TO A CCOMODATE PRECAST

PRECAST FRONT ELEVATI ON

The modified front elevation designed with precast concrete panels. With minor changesOldcastle was able to maintain the original design of the facade using precast concretepanels. This example shows the compatibility of precast concrete components and howthey can be used in place of common building products and still achieve the same design.

The modified front elevation showing only the exterior concrete panel components.

The original front elevation designed with a brick cavity wall.

1

2

3

LINCOLN UNIVERSITYLINCOLN UNIVERSITY PENNSYLVANIA


63/79

LINCOLN UNIVERSITY, PENNSYLVANIA

Pro jec t Descr ip t i on - Two phase, fourstory 120,000 SF residence hall. The precaststructure was erected during the middle of winter.


Lincoln UniversityGeneral Contractor:

EDIS Company, Wilmington, DE

Architects:AP3C Architects, Philadelphia, PA

Precaster:Oldcastle Precast Building Systems Division

III.

I.

Majo r Fea tu res -Total Precast Framing System:

Cross Wall System

7-inch Load Bearing Interior Panels


Stairs and Landings


LI NCOLN UNI VERSI TY


64/79

Grouting the base of an interior pre-cast wall panel

Interior precast stairs and landing Inter ior precast wall panels andplank along unfinished corridor

Infilling the shoring/bracing anchorsto provide a smooth wall ready forpainting

Setting a precast concrete floor plank Shoring of interior precast wall pan-els while floor plank is set andgrouted

Columns and beams at corner studyarea

Stairwell enclosure at end of build-ing

Winter erection of precast panels andplank

Exterior brick facade Completed Phase 1 on the right withPhase 2 panel erection on the left

Finished exterior building facade

1 2 3 4

5 6 7 8

9 10 11 12


65/79

TYPI CAL UPPER FLOOR LAYOUT


66/79

PARTI AL UPPER LEVEL FLOOR PLAN

PARTI AL STRUCTURAL FLOOR PLAN

1

2


67/79

PARTI AL FLOOR PLAN

ENLARGED TYPI CAL SUI TE PLAN

MELROSE COMMONS IIBronx, New York


68/79

Pro jec t Descr ip t i on - Affordable ownershipand rental housing comprised of 30 three-storytownhouse units with courtyard and off-street park-ing.

II. Pro ject Team -Developer:

MC II LLC, New York, NYBuilder:

Blue Sea Construction LLC, New York, NY

Architects:Equus Design Group, Inc, Belmont, MA(precast concrete design architects)Danois Architects. New York, NY(local architect-of-record)


III.

I.

Majo r Fea tu res -Total Precast Building System:

Exterior Load and Non-Load Bearing Panels Interior Load Bearing Wall Panels


Special Window Head and Sill Projections

Special Three-Sided Stairwell Channels

Exterior Stairs and Landings

Cornices

Embedded Brick FinishFormliner Finish (stone)Over 2,400 concrete pieces

Aw ards Rece ived - First affordable housing development in New

York State to receive Energy Star certifica-tions

National Association of Home Builders (NAHB)

HUD Secretarys Platinum award

NESEA Northeast Green Building first place

residential award

BSHF World Habitat Innovative Housing

database listing NAHB Energy Value Housing Silver Award

IV.

MELROSE COMM ONS I I


69/79

Pouring concrete panel with selfcompacting concrete over thin brickveneer

Power washing panel prior toshipping to job site

Exterior wall panel on truck readyto be shipped to job site

Non-load bearing front wall panelbeing erected

Precast entry channels and cornicesEndwall panel with embedded thinbrick veneer, water table and stoneformliner

Concrete channel being lifted intoposition

Initial pre-construction rendering

Precast cornice, entry channel andfront wall panel

Precast concrete projecting windowheader with concrete window jambs

Completed Melrose Commons IIaffordable housing

HUD Secretarys Platinum Awardfrom the National Association ofHome Builders (NAHB)

1 2 3 4

5 6 7 8

9 10 11 12


70/79

PARTI AL ELEVATI ONFLOOR PLAN LA YOUTS

SI TE PLAN STRUCTURAL PLANK LAYOUT

BASEMENT 1ST LEVEL 2ND LEVEL 3RD LEVEL

Mel rose Com m ons I I - Floor and roof planks spanned be-tween interior load bearing panels and exterior end unit walls. Non-

load bearing front wall panels and three-sided precast channel piecesenclosed the front of the housing units. Precast stairs and landingswere used between levels. A decorative precast concrete cornice com-pletes the facade.

21

3 4

CONDRON HALLUniversity of Scranton


71/79

University of ScrantonScranton, Pennsylvania

Pro jec t Descr ip t i on - Seven-story, 386-bedtotal precast concrete residence hall that containsover 108,000 sf of living space, erected in only four-teen weeks.


University of ScrantonArchitects:

Equus Design Group, Inc, Belmont, MA(precast concrete design architects)Burkavage Design Associates, New York, NY(local architect-of-record)


III.

I.

Majo r Fea tu res -

Total Precast Building System: Exterior Load and Non-Load Bearing Panels

Interior Load Bearing Wall Panels


Window Head and Sill Projections

Interior Stairs and Landings

CornicesEmbedded Thin Brick FinishConcrete Formliner FinishFormliner University Seal and Name

Over 500 concrete wall piecesOver 100,000 sf concrete plank

CONDRON HALL


72/79

Custom formliners were used tocreate embossed precast buildingname and University seal

Embedded thin brick in differentcolors and coursing patterns

Stairwell, dorm rooms and commonareas all clad with precast panels

Wide, unobstructed clear spansmade possible with precast spandrelpanels

Thin brick being layed in formlinerprior to pouring of concrete wallpanel

A combination of mitered and buttjoints used to create visual continu-ity

Exterior wall panel on truck readyfor shipment to job site

Projected concrete window framedopenings

Precast panels used to createprojections and recesses of themodulating facade

Precast concrete walls used for bothexterior and interior applications

A combination of formliner finish andembedded thin brick precast panelsused to create architectural interest

Building as seen from distant high-way entrance

1 2 3 4

5 6 7 8

9 10 11 12


73/79

TYPI CAL FLOOR PLAN LAYOUT STRUCTURAL LAYOUT

Condr on Hal l - Using a bearing wall System, floor and roof plankspan between interior and exterior load bearing panels. Load bearingendwall and stairwell panels are also used to enclose the ends of thestructure. Precast stairs and landings are used between levels.

21

University of DelawareNEWARK, DELAWARE


74/79

Pro j ect Descr ip t ion - This project, built in1971, is the first total precast high-rise studenthousing built in the United States. The two 17-story dormitories were designed to accommodate1,300 students. The towers have 375,000 SF andincorporate 255 one-bedroom apartment units and197 two-bedroom units.

II. Project Team -Owner:

University of DelawareGeneral Contractor:

Ogden Development GroupJoint Venture with Frederic G. Krapf & Sons,Inc., Wilmington, DE

Architects:Charles Luckman Associates, New York, NY

III.

I.

Major Features -Total Precast Framing System:

Cross Wall System

Insulated Load Bearing Exterior Panels

Load Bearing Interior Panels

Prestressed Hollow Core Floor and Roof Planks

Precast Columns, Beams and Stairs


Fluted FormlinerOver 5,000 Precast Concrete Components

UNI VERSI TY OF DELAW ARE


75/79

A total precast student dormitory The structure was erected at a rateof one floor per week per building

Eight-foot wide hollow core concretefloor and roof planks

Erection of a total precast buildingsystem

Wide corridors are made possiblewith steel headers for floor plank

Exterior wall panels contain foaminsulation cores which provide highthermal resistance

Combined precast stair and landings The exterior concrete panels werefinished with a light sandblast

17-story high-rise dormitory A storefront wall system is installedbetween concrete panels

The fluted formliner finish is outlinedby smooth spandrels and corners

Both high-rise towers as seen fromthe university campus

1 2 3 4

5 6 7 8

9 10 11 12


76/79

TYPI CAL FLOOR PLAN

TYPI CAL TW O BEDROOM APARTMENT PLAN


77/79

REFERENCES & RESOURCES


78/79


79/79

Opi Residential Manual

Documents

Transcript of Opi Residential Manual