Architectural Precast Concrete Wall Panels

Architectural precast concrete wall panels require reinforcement that provides structural performance while maintaining a high-quality surface finish. BarChip macro synthetic fibres were selected to reinforce these precast wall panels, delivering corrosion-free reinforcement together with improved manufacturing efficiency and consistent concrete performance.

Unlike conventional steel reinforcement, BarChip fibres are distributed uniformly throughout the concrete, providing three-dimensional reinforcement without the risk of corrosion. This makes BarChip particularly well suited to architectural precast applications where both appearance and long-term durability are important.

Architectural Precast Wall Panel System

The vertically formed architectural precast wall panels shown here demonstrate how fibre reinforced concrete can be used to produce durable, high-quality precast elements with an architectural finish. Available in a range of sizes and natural stone or brick finishes, these wall systems are widely used in residential, commercial and industrial developments, including highway noise barriers.

The combination of durability, construction efficiency and structural performance allows manufacturers to produce a wall system that delivers long-term value while maintaining an attractive architectural finish.

Each panel is manufactured in a controlled precast environment before being transported to site and mechanically installed onto a pre-constructed footing system. The precast wall panels pictured here are:

• 4 inches (100 mm) thick, 15 feet (4.6 m) wide and weigh between 6,000 and 8,000 pounds (2,700–3,600 kg).
• Available in 6, 8, 12 and 14 foot (1.8–4.3 m) heights with columns at 15 foot (4.6 m) centres.
• Rated to withstand 130 mph (209 km/h) sustained winds with gusts up to 150 mph (241 km/h).
• Reduce exterior noise by approximately 10.2 decibels.
• Manufactured using a concrete mix with a specified 5,000 psi (34.5 MPa) design strength.

Why BarChip was Selected

Precast wall systems such as this have traditionally used either conventional steel reinforcement or synthetic fibres. Fibre reinforcement can improve manufacturing efficiency, reduce reinforcement handling and deliver high-performance precast elements. However, not all fibres perform equally.

Following project testing and production trials, BarChip macro synthetic fibres were selected for three key reasons:

• Corrosion-free reinforcement – Unlike steel reinforcement, BarChip fibres are non-corrosive, eliminating the risk of surface staining or long-term deterioration caused by corrosion. This is particularly important for exposed architectural concrete.
• Improved concrete workability and consistency – Consistent concrete performance is critical in precast manufacturing. Working in consultation with BarChip specialists, the manufacturer optimised the concrete mix to achieve excellent workability, reliable production and a consistently high-quality finish.
• Excellent concrete performance – Quality control testing demonstrated excellent early-age concrete performance, with an average 1-day compressive strength of 3,100 psi (68.5% of design specification) and an average 7-day compressive strength of 5,405 psi (120.5% of design specification).

Combined, these benefits made BarChip the preferred reinforcement solution for both the designer and the precast manufacturer.