By definition, Fabcon manufactures precast non-composite wall panels. It’ll come as no surprise that we’re unabashed advocates for precast construction. It’s a field we helped pioneer nearly 50 years ago, and it’s still all we do. There’s obviously other ways to construct a building, and they all have their place…but let’s take the gloves off and see how other forms of construction stack up.
The advantages of construction with precast non-composite panels are many. Structural precast panels have made great strides in both function and aesthetics since they took off in the 1970s, and we continue to push the envelope today.
Fabcon’s structural designation is a critical component—it’s what separates how our buildings go together versus other forms of construction. Discover how Fabcon can add value to your building project.
Fabcon produces a variety of panel types and configurations. Our panels can function as structural (load-bearing) or architectural (non-load-bearing).
Even in the toughest conditions, we’re efficient. That means less erection time lost to harsh weather, more accurate lead times, and the ability to salvage projects that have fallen behind schedule.
Speed is a strategy. Our panels are cast while site work is being completed. Up to 250–350 linear feet of wall panels can be erected in one day to meet even the tightest schedules.
With Fabcon, there is less need for storage or staging areas on-site, leaving more room for other trades to maneuver.
Our panels offer structural stability that is resistant to dents, corrosion, and rust. They also require less maintenance without sacrificing aesthetics.
Fabcon’s superior, integrated insulating properties offer variable R-Values up to R-28.2 so you can right-size the thermal performance of your building.
At first glance, Pre-Engineered Metal Buildings (PEMB) may appear to be the cheapest building option. Sure, the price point of PEMB can be attractive to owners initially—but only when they neglect to look at the full, lifetime price of owning and maintaining their structure. Like fool’s gold, the shiny allure of a metal building may look good on the surface, but harsh realities may set in with the first severe storm or wayward skid steer.
Structural precast delivers may cost more initially, but a lifetime of superior durability and lowered operations costs cannot be oversold.
ISSUES WITH PEMB
— Hidden costs for structural columns and pier foundations can make quoted cost misleading
— Susceptible to damage from severe weather
— Easily damaged in settings where skid steers, forklifts are active
— Lifespan is considerable shorter than precast
— Many communities will not allow metal construction
— Often a small repair requires a complete panel replacement
— Higher risk to weather, fire and human-error affects insurance rates
— Insulation is usually inadequate, compromising comfort for occupants
A site-cast concrete wall system is typically cast on the building’s concrete floor slab or a nearby casting surface. The wall panel is formed and then poured at the job site. Once cured, it is tilted up and temporarily braced until the roof system is installed.
By contrast, Fabcon’s panels are manufactured in a controlled environment, ensuring proper and consistent curing.
CHALLENGES OF SITE-CAST CONSTRUCTION
— Site-cast can produce inconsistent quality.
— Rain and cold can alter the wall’s structural integrity, appearance and durability.
— Panel production speed and quality creation is weather-dependent.
— Site-cast panels lack integral insulation. The interior surface must be furred out and insulation glued or tacked to the interior surface.
— Limited aesthetic options when compared to precast.
— Floor slabs are often damaged during the casting process. The required repairs add additional time and cost to the job.
— Site-cast limits other trades’ access to the site and impacts the overall schedule.
— Panels exceeding 40′ pose serious engineering challenges.
— You’re only as good as your ready-mix provider.
Masonry’s relatively high costs, long construction cycles, and physical limitations cannot be ignored. Precast has serious advantages; delivery speed, energy performance, lifetime operating costs and even aesthetic options all fall in favor of precast.
Masonry construction has had good run, but it can be hard to justify these days. For many types of structures, masonry consumes too much time and too much money. Where block and brick fail, structural precast panels excel—and can even replicate the look of masonry.
CHALLENGES OF MASONRY CONSTRUCTION
Requires reinforcement at heights above 20′
Monopolizes work space on active job sites
Insulation is costly and requires additional subcontractor(s)
Extensive field man-hours needed
Susceptible to water penetration
Skilled labor shortage
Speed of progress is very weather-dependent
Slowest form of construction
Winter construction requires poly-tenting
Our panels are manufactured in a controlled environment
We can begin manufacturing panels before site work is completed (or even started!)
Fabcon panels are load-bearing
Fabcon Precast panels feature integrated insulation with R-values as high as R-28.2
Fabcon Precast panels can reach heights of 73 feet
Up to 250–350 linear feet of wall panels can be erected in one day to meet even the tightest schedules.
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