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