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Waffle-Crete Tech Info
 

Background

"Waffle-Crete" was first developed in 1976 by a precasting firm in Kansas. Since then, the concept has evolved into a building system with a large number of producers across North America that are licensed by "Waffle-Crete International Inc.". Advance Precast Ltd. produces "Waffle-Crete" at our C.S.A. Certified plant in Kelowna, B.C.


Panel Design

Sealed shop drawings are produced by Advance Precast Ltd. (using the latest AutoCAD software) for review and approval by Prime Consultants and the General Contractor. All panels are engineered by an outside firm to ensure the structural integrity of each individual building or project.


Concrete

35 MPa design, 75-100mm slump, 4-7% air entrainment, Type 10 cement, normal weight concrete.


Reinforcement

Shown on sealed shop drawings.


Panel Sizes

The standard "Waffle-Crete" panel is 8'-0" [2,438mm] wide and can be cast in any length up to a maximum of 40'-0" [12,192mm]. From single story to multistory buildings, the applications are virtually endless.


Opening Sizes

Rough openings shown on the plan are cast 1/4" [6mm] ( larger (unless marked EXACT) to compensate for minor amounts of out-of square and warping of the forming materials. For example, a window shown as 4'-0" [1,219mm] x 5'-0" [1,524mm] will be cast as 4'-0 1/4" [1,225mm] x 5'-0 1/4" [1,530mm].

Door openings assume a 2" [50mm] door frame. A 3'-0" [914mm] x 7'-0" [2,134mm] door will be given a 3'-4" [1,016mm] x 7'-2" [2,184mm] rough opening and an additional block out at the bottom to allow the concrete floor slab to be poured through the opening, where possible. When feasible, steel door frames are cast into the panels.


Dimensions

All dimensions for panel WIDTHS and HEIGHTS are NOMINAL dimensions, unless indicated as EXACT. Exact Panel heights are nominal dimensions (shown) less 3/8" [10mm] design gap. Exact panel widths are nominal dimensions (shown) less 1/2" (12.5mm) design gap. Unless noted otherwise, the floor elevation is assumed to be 100'-0".


Connections
  • PANEL TO PANEL:
Each panel to panel connection is fully-detailed on CAD Drawings. Typical panels are welded together at the top and mid-height of the panels, as well as grout tubes to connect to the foundation. Corners are welded.
  • WOOD TRUSS TO PANEL:
A top plate is bolted to the top of the panel, typically on 4' [1,219mm] centers using cast-in 3/4" [19mm] diameter bolt holes.
  • STEEL JOIST TO PANEL
A "truss pocket" can be cast into panel to allow the truss to sit on a steel bearing plate. Depending on the project, a parapet (change in height) may be used.
  • BEAM TO PANEL
A "beam seat" can be cast into the panel to allow the beam to sit on a steel bearing plate. In most cases, the precast panel can be changed in order to support the structural requirements of the beam (deleting the need for a structural steel beam). For small beams, a face weld plate with anchor studs allows for flush mounting of beams.
  • LINTEL CONNECTIONS
Lintels are welded to adjacent panels.

Miscellaneous
  1. Inserts cast into panels to stabilize trusses & fasten overhead doors.
  2. Weld plates cast into panels to stabilize adjacent steel columns.

Installation

Panels are set on shims and grouted under bearing surfaces. All panels manufactured by Advance Precast Ltd. are installed by our installation crew unless noted otherwise on CAD drawings.


Grouting

All load bearing surfaces under wall panels are to be grouted to distribute loads. A sand/cement mix is acceptable as long as good penetration is achieved. Any locations requiring a prepackaged grout will be noted on the plans.


Caulking

In vertical joints, use ethafoam backer rod and caulk with Sikaflex 1A or Dymeric caulking for the best adhesion of the caulk to the Precast substrate, and overall durability. (Both products have the advantage of being compatible with latex paints.) If other caulks are used, recommended products are: Dow Corning 795, Dymonic (by Tremco), and Silpruf from G.E. Use a Primer, as per manufacturer's recommendation.

Ensure that the person responsible for caulking installation is familiar with the temperature (at time of application) relationship and its effect on the performance of the sealant. Application of sealant should be one of the last items in the completion of a building, to allow time for the Precast to undergo initial shrinkage.


Transportation

Standard panels weigh an average of 45 lbs per square foot (220 kg. per square meter) and are shipped flat on standard trailers. For jobs outside the Kelowna area, Super-B train (98,000 lb or 44,492 kg) or B-train (80,000 lb or 36,320 kg) truck transport is the most cost-effective choice.

Panel Finishes

Four finishes are available:
  1. Smooth (Hand trowelled);
  2. Broomed;
    • Fine
    • Coarse; and
    • Striated
  3. Sandfloat (sold on the basis that it will be painted after installation as the finishing method used to obtain the surface texture creates a variation in hydration colors); and
  4. Exposed Aggregate (has a light sandy brown tome and we recommend spraying these panels with a methyl methacrylate sealer. The sealer gives a high gloss to the exposed rock and seals against moisture and stains).
NOTE: It is possible for us to produce "multiple" panel finishes on panels.

For good economy we recommend a broom finish with smooth area highlights.
 





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