Precast Concrete Sustainability: The Building Envelope

By PCI

Due to its density, concrete has the capacity to absorb and store large quantities of heat, contributing to a high-performance building envelope. Its thermal mass allows concrete to react very slowly to changes in outside temperature to reduce peak heating and cooling loads and delay the time at which these loads occur. The resulting savings can be significant - up to 25% of heating and cooling costs.

Thermal mass and energy savings

ASHRAE STANDARD 90.1 acknowledges the thermal mass benefits of concrete walls in specifying lower minimum insulation R-value and higher maximum wall U-factors for mass (concrete) wall construction.

Research conducted by Oak Ridge National Laboratory compared the dynamic thermal performance of insulated concrete walls with that of a traditional wood frame. Research shows that insulated concrete sandwich walls constructed with composite connector technology utilize the thermal mass effects of concrete to create an “equivalent wall performance R-value” several times greater than a traditional material R-value calculation.

Energy-saving benefits of thermal mass are most pronounced when the outside temperature fluctuates above and below the balance temperature of the building, causing a reversal of heat flow within the wall. The balance point is generally between 50- and 70-degrees Fahrenheit.

These ideal conditions for thermal mass exist on a daily basis at all locations in the United States and Canada.

Another factor affecting the behavior of thermal mass is internal heat gain. This includes heat generated inside the building by lights, equipment, appliances and people; and heat from the sun entering through windows. Generally, during the heating season, benefits of thermal mass increase with the availability of internal heat gains. During the cooling season, thermal mass exposed to the building’s occupied spaces will absorb internal gains, shifting peak cooling periods. Concrete exposed to the interior, not covered by insulation and gypsum wallboard, works best to absorb internal gains, saving cooling energy.

Color

Color (albedo) of precast concrete panels can be used to improve the energy-conserving features of the walls. Panels with high albedo (generally lighter in color) can help reduce the urban heat-island effect. Albedo is the ratio of the amount of solar radiation reflected from a material surface to the amount that shines on the surface.

Generally, materials that appear to be light colored have high albedo and those that appear dark colored have low albedo. On exterior surfaces, high albedo decreases solar heat gain; low albedo increases solar heat gain. A low albedo north wall and high albedo east and west walls and roof form the most energy-conserving arrangement in a northern hemisphere climate that uses both heating and cooling. High albedo surfaces are especially important where cooling dominates the energy requirements. It should be noted, however, that the color of the exterior walls has less affect on energy consumption when the walls have high R-values and thermal mass.

Heat-island effect

Light-colored exterior surfaces also help reduce urban heat-islands. Urban areas are up to seven-degrees Fahrenheit warmer than the surrounding areas. This difference is attributed to more buildings and pavements that have taken the place of vegetation. Where buildings and paved surfaces are required, using materials with higher albedos will reduce the heat-island effect, save energy by reducing the demand for air conditioning, and improve air quality.

Air infiltration

Air infiltration has significant effects on the amount of energy required to heat and cool a building. Large precast concrete panels have minimal joints, reducing uncontrolled air infiltration.

Women in Construction Week: Kristen Heiser

Mid-States Concrete Industries celebrates Women in Construction Week (March 6 – 12) by highlighting women on our team making their mark in the construction industry.

Today we feature Senior Project Designer Kristen Heiser, who has been with Mid-States Concrete for 15 years.

“In high school, I kept rearranging my room and I wanted to rearrange the living room, but my dad wouldn’t let me,” Kristen said. “High school had a board drafting class and that was that. And then it became a computer course, AutoCad 1, and I liked it, so I went for my major in CAD work.”

In her role as Senior Project Designer, Kristen takes contract drawings and then creates shop drawings for our team, which include all the pertinent information they need to appropriately manufacture and install the precast components.

“No two jobs are the same,” Kristen said. “It’s always different. Even similar jobs are not similar… They all have different requirements.”

What Kristen enjoys about precast is that it is always evolving. The buildings are getting bigger, and more complicated. It’s not just straight beams anymore. This is also one of the biggest challenges of her job.

When Kristen reflects back on all the buildings she’s worked on – two stick out. The first is the very first project she ever did for Mid-States. It was a two-story golf clubhouse at a country club and there were no straight lines, everything was angled. And while Kristen worked off of dimensions that were taken in the field by her fellow Mid-States team members, when the pieces got to the site, they didn’t fit. This resulted in tons of section cuts, but in the end the project turned out just fine. Luckily, Kristen’s following projects didn’t have the same issue.

The other project that stands out is St. James Church in Belvidere, because she and her son attend that church. She knew the project was one Mid-States would work on and started asking around, inquiring whether she could serve as the designer on the project. She ended up getting the drawings from the sales team on Ash Wednesday. The project was unique as a formliner was used on the wall panels to match the stone of the then 104-year-old church. It was also one of Mid-States Concrete’s first jobs that used C-GRID, and had the added complexity of the openings for the stained glass windows.

Kristen has grown used to working in a male-dominated field as even early on she was often one of the only women in her classes, but she thrived.

“The guys knew I knew what I was doing and they’d come ask me for help,” she said.

In terms of advice for other women looking to get in to the field: just go for it. If that’s what you like to do, there’s no reason you can’t do it.

Women in Construction Week: Wendy Mendiola

Mid-States Concrete Industries celebrates Women in Construction Week (March 6 – 12) by highlighting women on our team making their mark in the construction industry.

Today we feature Field Scheduling Manager Wendy Mendiola. Wendy celebrates her 19-year anniversary with Mid-States Concrete in March.

In her role, Wendy coordinates anywhere between 30-70  loads going to multiple job sites daily, as well as seven installation crews daily, and all FOB and FOB Yard jobs (usually at least one/day). With the help of the project management team, Wendy puts together the field schedule, creates the shipping schedule, sets up trucking for every load, including the timing of truck arrivals to the yard and jobsite, makes the daily field crew schedule so they know exactly where they are going and what they are doing every day, and coordinates any extra equipment the crew may need.

Wendy communicates with the field team all day long to help keep everything progressing and everyone on the same page.

“It’s definitely not a job for someone who doesn’t handle change very well,” she said.

Over time, several of Wendy’s family members have worked at Mid-States (and several still work here) and it was through those family members that Wendy first came to be part of the Mid-States team. Wendy was first asked to join the team when a team member was out on military leave. The team liked her so much, they asked her to stick around even after that team member returned. Over the years, Wendy has worked in several roles, including field coordinator and production scheduler.

“Working through the daily, sometimes hourly, changes that can occur within the construction industry is a challenge,” Wendy said. “I’m so grateful for the experience I’ve gained and the team I’m part of for showing me how to adapt to all the changes and I do enjoy the challenge of handling it all.”

Wendy added that the entire project management team has been great at helping Wendy learn how to effectively communicate all the changes that occur on a regular basis – it is the construction industry after all – especially when talking with customers.

“I care a lot,” Wendy said. “Sometimes I take things way too personal and I know I need to try not to take things personally or take it home with me at night.”

As a woman in a male-dominated industry, Wendy has come a long way over the years and has earned the respect of those she works with. She put in the time and the work to learn the job and the company-workings inside and out to effectively serve customers.

In terms of advice she would offer other women looking to get into this type of work: have a strong personality because you are going to have to stand up for yourself and the company. There are going to be conflicts, she said, and you have to work through them professionally.

Women in Construction Week: Luisana Garcia

Mid-States Concrete Industries celebrates Women in Construction Week (March 6 – 12) by highlighting women on our team making their mark in the construction industry.

Today we feature Project Detailer Luisana Garcia. She has been part of the Mid-States team for just over a year. In her role as project detailer, Luisana is responsible for creating piece component drawings for all of our products – beams, columns, hollowcore, wall panels, etc. She works closely with our project designers and our project engineers.

“I like to be part of the life of a building project, seeing how it develops until it reaches the total construction of the building is poetry for me,” Luisana said. “I enjoy detailing these components because it is a fundamental part of the building, and I am passionate about knowing that I am doing my best to bring that building to reality.”

While Luisana enjoys her work, it isn’t without its challenges. The biggest challenge she faces is to create the drawings without any errors. To do this, she takes the time to review project requirements and make sure that each piece she details has everything necessary to be built.

Although a female in a male-dominated field, Luisana doesn’t like to characterize herself that way. Rather, she focuses on giving her best, preparing herself to be competent in her work and utilizing her knowledge to be part of the legacy she wants to leave. She wants to be the best at what she does and continue to learn something new every day.

She looks to Marie Curie for inspiration. Marie said: “You cannot hope to build a better world without improving the individuals. To that end each of us must work for his own improvement, and at the same time share a general responsibility for all humanity, our particular duty being to aid those to whom we think we can be most useful.”

As far as advice Luisana would offer other women looking to get into the field: find your passion and no matter what you choose to do, choose to be happy doing it.

Women in Construction Week: Tracy Miller

Mid-States Concrete Industries celebrates Women in Construction Week (March 6 – 12) by highlighting women on our team making their mark in the construction industry.

Today we feature Safety Manager Tracy Miller. Tracy has been on the Mid-States team for eight-and-a-half years. In her role, she oversees all things safety. From providing safety training to all new team members during orientation to regular plant and field audits on safety, housekeeping, and compliance to writing and implementing processes and constantly updating Mid-States Concrete’s safety procedures to keep all of our team members safe, Tracy is our go-to person.

Prior to joining the Mid-States team, Tracy worked as a tech on the line at Lear. While there, she got heavily involved with the Union, which then pushed her to get even more involved and led her to going to school to get a bachelor’s degree in human resources. When she joined the Mid-States team, it was in an administrative assistant role that helped both HR and production.

In 2016, her role started to evolve more to the safety side of things and she helped to create a safety team. This allowed for more audits and compliance, as well as more training out on the plant floor. Currently, she and her team are working on revamping work instructions and processes to find efficiencies.

“I love that it is different every day so I don’t just come in every day and do data entry or whatever,” she said. “There is always something going on.”

Tracy’s favorite part of her job is completing safety audits because she always learns something, especially if she goes out in to the field because it is different from her day-to-day at the plant. She said it is challenging to make sure she is up to date on all the regulations with everything constantly updating or changing.

Being a woman in a male-dominated industry has never really bothered Tracy. In fact, she hardly ever notices she’s the only woman around even though she rarely runs into another woman in the field. However, she has noticed when she gets mad or frustrated, it is sometimes perceived differently than if a man gets mad or frustrated.

“I’m just passionate about my work,” she said.

As far as advice Tracy would give to others looking to get in to the industry: keep your mind open to learn from others and listen, and don’t take things personally. If someone breaks a rule, it isn’t that they dislike you, it’s that they were distracted and weren’t focused on what they were doing. Being safe is thinking with intent, doing the right thing when nobody else is around.

“You have to have a lot of patience in safety,” she said.