Want quick responses to our most asked precast questions? PCI-MA is kicking off a blog series called, “FAQ Fridays,” in which your most popular questions are answered and organized by topic and product category. In Part 1 of this series, we discuss precast concrete design options and aesthetic versatility.
Precast concrete offers a virtually unlimited palette of options for creating unique aesthetic treatments when taking on a historic feel or blending in with a contemporary style. It combines aesthetic flexibility with practical benefits, making it a top choice for architects and builders aiming to achieve specific visual outcomes while adhering to budget and durability requirements.
The use of precast concrete not only facilitates a wide range of design possibilities but also offers structural benefits that other materials cannot match, such as enhanced strength and reduced maintenance costs.
Let’s take a look at aesthetic options and types of concrete finish techniques available with precast cladding and building enclosure panels that enhance both the functionality and visual appeal of projects.
What Are the Aesthetic Possibilities of Precast Concrete?
Precast concrete is not only celebrated for its structural integrity but also for its vast array of aesthetic possibilities. This versatility allows architects and designers to achieve a tailored look that can mimic traditional materials like brick and stone or provide innovative, custom colorations and textures.
Whether integrating into historical surroundings or defining a new contemporary landmark, precast offers unique forms and concrete finishes that blend beauty with practical benefits like durability and cost-effectiveness. Some options can include: brick, stone replication, and colors/tints.
Brick
Using inset thin-brick techniques on precast concrete panelized systems creates the masonry appearance that building owners seek while adding benefits masonry can’t provide. Precast’s inset brick eliminates the long scheduling needed for laid-up brick while removing several trades from the site. It ensures a high-quality, even-spaced appearance that is difficult to achieve with actual brickwork, while eliminating on-site inspections. Using inset brick with precast concrete panels makes efficient use of materials, minimizes time and construction materials, avoids problems with weep holes from falling mortar, and eliminates concerns over inconsistent labor expertise, weak mortar joints, efflorescence, and disruption due to inclement weather.
Stone Replication
Special mixes and finish techniques are used on panels to mimic limestone, sandstone, granite, or other types of stone. The finishes are produced far more economically than real stone can be laid, and they can be erected much quicker. Formliners replicate unusual pieces such as cut stone or slate, limiting options only to the designer’s imagination.
Colors/Tints
Precasters’ capability to tint concrete and provide several tones by using various surface treatments within one panel allow designers to specify any color they want. A wide range of finish combinations and textures can be achieved easily.
What Creative Finishes Are Available with Precast Concrete?
A wide variety of concrete finishes and textures can be created when designing with precast to add interest to the final product. The most common precast concrete finish options include: smooth/off-the-form finishes, exposed-aggregate finishes, formliners, sand/abrasive blasting, acid etching, honing/polishing, painting, or a combination of the aforementioned.
Smooth or off-the-form finishes
This finish retains the natural aesthetic of precast concrete texture and color without any attempt to simulate other materials. It is characterized by a clean, unadorned look that comes directly from the mold, making it ideal for projects where simplicity and modernity are key design elements.
Exposed-aggregate finishes
Achieved through methods like chemical retarders or water washing, exposed-aggregate finishes bring out the rich colors and varied textures of the course aggregates used in the concrete. This technique highlights the natural beauty of the stone within the concrete, offering a durable and visually appealing surface that is ideal for both interior and exterior applications.
Formliners
Formliners are used to imprint intricate designs and textures into the surface of precast concrete. Available in materials like wood, steel, and various plastics, formliners can replicate everything from natural textures like stone and wood grain to geometric patterns, adding a custom aesthetic to the concrete surface.
Sand or abrasive blasting
This process involves blasting the surface of the concrete with sand or other abrasive materials to alter the finish. Depending on the degree of blasting, it can lightly roughen the surface or expose the aggregate for a more textured appearance. This method is perfect for creating slip-resistant surfaces or adding visual depth to the concrete.
Acid etching
Acid etching uses a mild acidic solution to remove the thin layer of surface cement, revealing the fine sands beneath while barely exposing the coarse aggregates. This results in a subtly textured surface that is less pronounced than sandblasted or exposed-aggregate finishes, offering a soft, matte look that can complement a variety of design styles.
Honing or polished finishes
These finishes are achieved by mechanically grinding the surface of the concrete to a smooth sheen, exposing the aggregate within. The result is a glossy, refined finish that adds a touch of elegance and sophistication to the concrete, making it suitable for high-end architectural applications.
Painting
When a more vibrant or specific color is desired, painting precast concrete is an option. It is crucial to prepare the surface adequately to ensure good adhesion of the paint. This finish allows for a broad range of aesthetic options, from bold colors to detailed artistic designs, expanding the design flexibility of precast concrete.
Combination Finishes
These involve applying two or more finishing techniques to the same concrete unit, enhancing its aesthetic appeal and texture. While this method can increase production costs, it is often more economical than creating multiple separate units with different finishes. Combination finishes allow for creative design solutions, blending textures and effects to meet specific architectural visions.
Designing with Precast Concrete Textures & Finishes
Precast’s plasticity and variety of concrete finishes make it an outstanding choice no matter what style of architecture is desired. Ensuring the proper look is achieved can be made easy with precast concrete.
Even parking structures can take on a unique appearance when working with precast. Designers can be purposeful in integrating a parking structure into the surrounding architecture. Learn more by reading through our common precast concrete parking structure FAQs.
Precasters can provide finish samples, range samples and large-scale mockups, ensuring design concepts translate into reality. Designers can inspect window interfaces, joint connections, and other critical elements to ensure they are visually acceptable and will properly interface between trades. Plant visits to discuss technical and aesthetic concerns provide control without requiring constant site supervision. Find helpful design considerations for precast installation and erection in our precast concrete installation FAQs and precast concrete wall panel FAQs.
As the single source for so many architectural and structural components, and the source for brickwork or other finishes, the precaster works closely with the construction team to ensure satisfaction. Overlapping trades and gaps in responsibilities are eliminated when the precaster provides the entire exterior design.
As you can see, the design versatility of precast concrete allows for almost any shape element, such as curved and radial sections, with flexibility in connection points and load paths. High strength prestressed concrete structural members also deliver exceptional load-carrying capacity, which can result in smaller sections, longer spans, or both when compared to other structural systems.
Click these links to explore our case studies and project profiles, which are stellar examples of architectural precast in the Mid-Atlantic. Find helpful tools, detailed information on working with precast, and expert guidance to support your next projects at our Solutions Center.
PCI has also developed several Designer’s Notebooks that can help you get started. These publications are available for download in PDF format and free of charge.
