Precast vs. CIP: What Makes the Most Sense for Your Project?

There’s no question that concrete is one of the longest-lasting and most economical building materials. The fact that concrete actually gets stronger over time makes it a winner over other construction materials, like wood, for example. Believe it or not, there are actually 23 different types of concrete used in today’s modern construction industry. These types can be used in different applications to achieve a variety of results. But today, it’s the process we want to discuss: Precast concrete versus cast-in-place (CIP) concrete. What’s better? To answer that question, let’s take a look at each process, the advantages of each and, of course, your desired outcome. 

What is Precast Concrete? 

Precast concrete products are cast at a factory. The concrete, a mixture of cement, water, aggregates and admixtures, is placed into a form and cured before being stripped. These products are then delivered to the construction site for erection into place. Precast products can include concrete bricks or stones, structural components and wall panels, to name just a few.

What Are the Advantages of Precast Concrete? 

The benefits of precast concrete are most notably speed, durability, efficiency and quality. However, perhaps the most important characteristic is the material’s flexibility. Precast concrete can be used in a variety of applications making it appealing to architects, developers, general contractors and designers alike.

Working with precast concrete offers the following advantages:

• Speed: Not only can products be cast while foundation work is in progress, but precast concrete components can be cast and erected year-round regardless of weather conditions.
• Durability: Concrete is by nature a highly-durable material that is resistant to wear, weather and damage.
• Energy Efficiency: Concrete’s high thermal mass conserves energy, and the use of insulated panels only enhance that attribute.
• Environmentally Friendly: Precast concrete is clean and waste-free, and the addition of by-products reduces requirement for cement in the mix, as evidenced by the ability to obtain LEED certification.
• High Quality: Since products are cast in a factory, quality control is very high and allows for a single source provider.
• Aesthetic Flexibility: Precast can mimic granite, limestone, brick and other masonry products and can be finished in variety of textures and colors.
• Design Flexibility: Precast concrete members can handle higher loading and longer span capabilities providing more flexibility with office and parking structures.

What is Cast-in-Place (CIP) Concrete? 

CIP (or site cast) concrete is prepared at local plants for construction site delivery via trucks with revolving drums. Once the concrete arrives, the walls and slabs are cast at the site in the formwork. CIP concrete requires a strength test and additional time for curing on-site. Sometimes it can be hard to control the mix when weather conditions are a factor.

What Are the Advantages of CIP Concrete? 

Strength, reduced transportation and insulation are the primary benefits of site cast concrete. While concrete is an inherently strong material, CIP concrete is preferred for laying foundations and basement walls. It is also relatively resistant to structural damage due to earthquakes, floods or other natural disasters. Since site cast concrete is cast at the construction site, there is no need for transportation of finished products. On the flip side, this process requires more labor onsite to ensure proper and timely pouring, molding and curing. Finally, since this type of concrete is poured on-site, there is a fewer occurrence of natural cracks or gaps between walls leading to insulation properties that extend to insects, mold and mildew.

Designing with Precast Concrete 

Developers, architects, designers and contractors come together on a building project to achieve a desired outcome. Usually each party has several challenges to overcome and the desired outcome is a cohesive look and feel that capitalizes on function and efficiency. Here’s some common issues that may arise during the planning process and how precast concrete can offer a solution. Check out the Precast/Prestressed Concrete Institute (PCI) design resources for more information.

How can I ensure sufficient structural support for computer and storage systems in an office building or distribution center? High-strength flooring provides support for heavy loads now and in the future. Take a look at this data center.

Can using precast concrete increase energy efficiency? Yes, the material’s inherent thermal mass helps regulate temperatures but insulated precast concrete sandwich panels provide added energy efficiency due to insulation in the core.

 How do I minimize congestion and safety concerns on-site and in the general vicinity during construction? Since precast concrete products can be delivered to the site as needed for that day’s erection, staging areas can be arranged nearby ensuring less traffic on-site and less congestion in the vicinity.

Can I create tall, open interiors with precast to allow for flexible merchandising space? Yes, architectural precast concrete panels can be designed to provide high ceilings. Check out this retail project.

What about delivery docking space? How can I accommodate trucks? Precast concrete panels’ capability to be cast in 12-feet widths or wider allows docking doors to be built into a single panel, providing inherent stability and fast erection. Take a look at this cargo center.

Can precast concrete materials help me create a design that complements surrounding buildings while also meeting brand requirements? Architectural precast concrete panels use colors, textures, reveals, finishes, form liners, or thin-brick insets to match any needed design style. These looks can be used for warehouse type retailers, additions to malls, stand-alone stores and more.

How can I design open interior spaces to maximize parking layout and provide a secure environment? Double tees can span long distances to eliminate columns and provide unobstructed view through the levels. Moment frames, k frames, lite walls and other unique structural supports can open interiors and smooth traffic flow. Check out this open parking deck.

How do I create high fire resistance? Precast concrete’s non-combustible composition minimizes the spread of fire, while compartmentalization design techniques provide time for detection, evacuation and suppression.

How can I create long-span areas like gymnasiums and pools? The use of precast hollow-core slabs and double tees can span long distances to minimize or eliminate columns where needed. Take a look at this recreation center.

What about noise? Can using precast concrete materials control acoustics? Yes, precast concrete wall panels, especially insulated panels, minimize noise between units.

I’m working with strict zoning requirements. How can I minimize floor-to-floor heights? Hollow-core slabs can serve as a combined ceiling/flooring unit, reducing the building’s height.

There are many factors to consider when choosing materials – and partners – for your project. Precast concrete continues to evolve as designers expand the applications of the material. ATMI Precast is a full-service precast construction company. We service a broad spectrum of project types, from mid-rise office to residential and parking and look forward to working with partners who will push the boundaries and create innovative projects. Long recognized as a leader in the field, ATMI Precast has earned customer recognition for our reliable performance, quality and service throughout the precast concrete construction process.

Is precast concrete a good fit for your project? Contact us today. We’d love to work with you!