Precast Walls Above Ground

Superior Walls concrete panels arrive on site with door and window openings precut according to the plans the builder supplies.

It's not easy to make changes on the fly to the concrete panels, so plans need to be accurate.

For the footing, a trench is lined with drainable geotextile filter fabric, filled with crushed stone, and roughly leveled.

The crew places the 8,000-pound panels using a crane. They establish the first corner and make sure it's plumb.

Setting the walls for one story takes about half a day.

The joints between the panels are sealed with an industrial-grade urethane-based sealant.

At wall corners, panels are bolted together with through-bolts.Preformed lap joints on adjacent in-line panels are fastened using a bolt and a steel fitting.

The ground inside the wall system is prepped for the poured slab.

Superior Walls panels have a 3 1/2-inch-deep “rim ledge” at the inside top of the wall, completely within the wall’s exterior skin, wherever the floor system needs to bear at the exterior wall.

A 2x4 on the flat is cast into the pocket formed by the "rim ledge" as a nailer and bearing shelf.

Upper-story walls require less preparation, since there isn’t any groundwork involved.

Three to four hours on site with the crane, and the Superior Walls crew is gone again.

On this project, the Superior Walls crew set the gable end panels on the same day as the upper-story wall panels.

The framers framed the roof using a system of girder trusses and purlins.

The underside of the 5/8-inch plywood roof sheathing is insulated with 3 inches of sprayed closed-cell polyurethane.

The closed-cell insulation helps glue the roof deck to the structure and make the roof-to-wall joint airtight.

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