return piece is removed from its form and is connected to a
master mold. The return is cast monolithically to the master
piece. Two-stage concrete placements create a more uniform texture on all sides of the panel. A quirk should be provided in the corner so the return is not formed to a sharp edge that is easily chipped. The details for casting individual panels should always be left to the precaster. Elevations, wall sections, and details of each different type of wall panel should be drawn by the architect. When using large elements, if the appearance of smaller panels is desired for aesthetic reasons, false joints (rustications) can be used to achieve this effect. At times a compromise may be required between the finish and the shape of a precast concrete panel. Wherever possible, the designer should avoid fragile edge details. Chamfered or eased edges reduce edge damage and mask minor irregularities in alignment. 2.2.4 Panel Size and Panelization Precast concrete pricing is determined primarily by the size of the pieces and repetition. Pricing is more dependent on large pieces than on a large project. For example, a 100-piece project of large panels can be less expensive per square foot (m2) than a 1000-piece project using much smaller panels. The reason piece size is so important is because most labor functions performed by an architectural precaster and erector are required because of the existence of a piece. The more pieces the project has, the more labor hours it will take to engineer, cast, strip, finish, load, deliver, and install the panels. Therefore, it is more economical to enclose a larger portion of the building s exterior with fewer precast concrete panels (see also Section 3.3.10). For maximum economy, minimize the number of pieces by making them as large as possible within normal manufacturing and shipping limitations. Handling and erecting precast concrete components constitutes a significant portion of the total precast concrete expense. The cost difference in handling and erecting a large rather than a small unit is insignificant compared to the increased square footage of a large unit, Table 2.2.2. To be economical, a project s average piece size should be at least 100 to 150 ft2 (9 to 14 m2) and, ideally, larger than that. There is no exact optimum panel size. Usually the optimum panel size is dictated by size and weight limitations imposed by transport (for example, weight restrictions and bridge or power line clearances), site access, or crane capacity. The panel size is also a function of the design loads and support locations for connections. Close collaboration between the designer and a precaster is required during the early stages of a building s design to determine the optimum panel size or panelization scheme. Piece sizes that require highway permits for over height, width, length, or weight generally should be avoided. There is a balance between maximizing potential economy of the faade elements and maintaining the economy of the supporting structural system. The key
is to recognize where localized loads will occur. Often
the added cost of local reinforcing of the supporting structure that may be required to accommodate larger precast concrete panels will be more than offset by savings that result from erecting fewer panels. The designer can ensure a good average piece size by spanning a full bay with spandrels, and designing multistory column covers and large wall panels. Designing larger panels, even though they may carry a hauling premium, may be the most cost efficient. For example, an office building with 30 x 30 ft (9.1 x 9.1 m) column spacing requires fewer columns and concrete panels and yields a more wide-open interior than the same building with a 20 or 25 ft (6.1 or 7.6 m) column spacing. The cost premium (if any) to haul two 30-ft-long (9.1 m) panels versus three 20-ft-long (6.1 m) panels usually can be more than overcome by cost savings in other manufacturing areas like engineering, production, and installation. The typical parking structure may have perimeter panels that are 60 ft (18.3 m) long