Large-scale construction projects stand in a class of their own, requiring materials that are flexible, efficient, and durable to meet the demands of these buildings. Precast concrete walls are known for their many benefits and standing out as a versatile, reliable material in a commercial space.
Precast concrete walls are concrete structural elements cast and cured in a controlled manufacturing environment, which are then transported to the construction site for installation.
At XL Structural, we’ve worked on many projects that have spec’d for precast walls. We’re often asked why people would go with precast concrete over other methods, and whether building with precast is the right option.
While precast walls can cater to your specific operational needs and provide extra advantages over and above other concrete and building materials, it isn’t a solution for every project.
In this article, we explore when and why using precast wall(s) in your industrial commercial build is a good idea. We also outline key considerations and what to expect when you do.
Same but different: Precast vs Tilt up concrete
Often confused because of their shared use in construction, precast and tilt-up concrete differ significantly in the way they are manufactured. Off-site pre-casting involves pouring concrete in a controlled factory setting, ensuring quality control, and minimising waste.
In contrast, tilt-up construction involves casting panels on-site before lifting them into place, offering a practical solution for remote sites far from precast facilities. However, they do present challenges, such as slower progress and potential quality compromises due to uncontrollable site conditions.
Since pre-casting off-site offer strong cost and quality control advantages, it is generally the preferred option.
Why Choose Precast WAlls?
durable
Precast concrete walls are one of the most durable wall systems. They can endure vehicle impacts and require minimal upkeep compared to other cladding, making them ideal for industrial settings. Even in demanding and high-use equipment environments, they maintain their appearance and strength, due to their steel reinforcing and high strength/MPA concrete to meet modern building and earthquake codes.
Versatile and visibly appealing
Precast walls offer a unique blend of design flexibility and aesthetic appeal. With the ability to be made in various heights, shapes, and sizes, they give builders and architects the freedom to create visually striking buildings. Additives and customisation techniques can be used in a factory environment, allowing you to pick from almost endless designs and finishes so the product aligns with your brand.
Examples of this can be as simple as painting, right through to surface finishes like exposed aggregate, wood grain, or etched in murals, logos, or names.
Secure
The strength of precast concrete adds a level of security that can prevent both break-ins and resist most impacts. This means it isn’t susceptible to vehicle ramming, cutting into, or unscrewing cladding panels to gain access. Precast concrete has also become a default material for creating storm shelters. For your larger construction project, precast concrete will deliver a safer product that can withstand the harshest of elements and unforeseen circumstances.
Engineering insights
The controlled production process ensures consistent quality and precision, reducing gaps or inconsistencies during installation. As the walls are cast, they can be designed precisely to what is needed. Due to its strength, precast concrete can be used in load bearing walls, reducing the amount of steel required. This delivers a cost saving as well as a robust building structure.
Precise engineering means the walls are made to exact specifications, contributing to its structural integrity. Reinforcement is also specified precisely by the engineer to account for wind, earthquake, and seismic loads. There have been considerable increases to the loads and requirements following the Christchurch earthquakes, where a lot of concrete structures performed poorly. Reinforcing is also part of the offsite manufacturing process, which adds to the efficiency of pre-casting offsite.
Precast concrete is resistant to fire, making these walls an excellent fire safety measure. Combined with the right insulation and panelling on walls and ceilings, it can limit a fire’s ability to spread between rooms and provides continuous support to the structure even under extreme heat conditions.
It will come as no surprise that precast concrete walls are also excellent sound barriers. They absorb, block, and reflect sound waves, reducing the impact of noise from within the building, and reducing any outside noise.
Cost vs time
The installation speed of precast panels can shave months from a construction schedule, drastically reducing the construction financing cost. Analysing the costs of your precast concrete wall accurately will help you understand the expenses within the project's full lifespan.
It's also important to consider the initial costs against long-term savings in maintenance, durability, and energy efficiency offered by precast concrete. Effective budgeting ensures your project stays financially viable, while maintaining quality and safety. It also allows for smarter financial choices, pinpointing areas for cost optimisation without affecting the project's integrity or timeline.
Planning for precast Walls
Precast walls are often required in certain industrial builds to meet fire safety requirements. Engineers and fire designers will assess and calculate the specific requirements for your project. At XL, we have in-house fire design expertise so we can review your project and determine what is required. To find out more about what your options are, read our article on fire here.
Your engineer will also consider if the weight of your panels will have any implications on the foundations of your building. While panels generally require concrete cantilevered foundations for fire rating compliance, when subjected to seismic loads, it's more efficient for panels to be bolted to a steel structure to maximise the efficiencies of the building foundations.
In instances where precast walls are used in areas with poor ground conditions, specialised foundations such as piles may be needed to support the additional weight effectively. Designers need to carefully optimise the foundation designs to accommodate the requirements of precast walls and ensure the structural stability of the building.
The choice of precast concrete walls for your industrial build demands an assessment of multiple factors. While precast concrete can present advantages, it's important to be aware that it may not be the perfect solution for every project. Before committing to precast concrete, you should weigh up its benefits against the specific needs of your build, with the help of a designer, engineer and build team or lead consultant.
At XL Structural, we're committed to guiding you through this decision-making process, providing expertise and insight tailored to your unique project needs. If you're planning your next industrial building project and want to speak to an expert about the process, reach out to our team today.
For more details on the cost of choosing precast concrete walls, try our budget estimator tool to see estimated costs for your project. 
