Problem

From the very beginning, this project was defined as a challenge but fortunately, the entire team was ready. The congregation faced limited funds and a very specific exterior facade requirement: the precast layout had to accommodate the intricate arches, inlays, and face relief in the original Ancient Egyptian Coptic architecture. COVID-19 limited the team’s ability to discuss design options with the congregation in person. Then, the resulting supply chain challenges limited the availability of the brick required to match the existing building.

Solution

To address these challenges, the design team incorporated precast concrete for the exterior wall systems. They chose this solution because it was insulated and could be left exposed on the interior while maintaining the same architectural features as the original church, including intricate arch details, soporific brick patterns, and brick colors. Precast concrete enabled the creation of an intricate exterior and finished interior that could not be accomplished with other products or construction methods. Further, precast is inherently non-combustible and resilient to weather impacts, giving the congregation confidence the addition would stand the test of time as effectively as the original building.

The structure features total precast with insulated load bearing exterior walls with a multi-tiered running bond brick along with arched and slot windows to match the existing structure. It also boasts as-cast gray precast that was applied with a hand trowel as the interior finish. Using Building Information Modeling (BIM) enabled the precast to be fully coordinated for fabrication and virtually eliminated any issues with fit up, missed connections, or conflicting details.

Results

The use of precast enabled the team to accomplish all the building core and shell requirements without impeding or limiting its layout. Precast solid walls and hollow-core plank frame the main level over the basement and two more levels of classrooms above. And the gym features an 82’-0” clear span double T member that provides the church with a shallower and more resilient structural system than conventional construction methods.

Given the walls were a finished product, electrical items were embedded in the precast as it was cast. The project technician, with the help of BIM, coordinated approximately 90 electrical boxes and conduit runs, allowing for easy ticketing and location of the boxes both in the model and fabrication tickets and eliminating the need to fur out walls to install electrical outlets, lights, or switches.