FAQ
How long has Fabcon been in business?
What kind of precast does Fabcon make?
What quality assurance programs does Fabcon have?
Does Fabcon conduct research and Development?
Where do you produce Fabcon wall panels?
Will Fabcon perform as Engineer of Record?
Does Fabcon use union field crews?
Does Fabcon make the connections between the precast and the steel?
How long does it take to get Fabcon panels to the jobsite?
Does the steel have to be erected prior to the precast installation?
Does Fabcon set the steel and/or pour the footings?
What is a Fabcon’s definition of a keyway?
Does Fabcon have other footing details?
Where does Fabcon use grout and what type of grout?
Do you caulk Fabcon wall panel joints?
Are Fabcon wall panels better than block?
How is precast different or similar to site cast?
What is Fabcon’s price per square foot (wall surface area)?
Are Fabcon’s Wall Panels sustainable?
How can Fabcon help me qualify for LEED’s certification?
How are the weight efficiency and increased R-Values accomplished?
How thick are Fabcon’s wall panels?
How tall are Fabcon’s wall panels?
Are Fabcon products structural or architectural?
What kinds of finishes does Fabcon’s offer?
What imprint patterns are available?
What are our minimum and maximum band widths?
What angle can the edges of the reveal be?
What colors are available in the wall panels?
Are sandblasting or acid-etched finishes available?
What is Fabcon’s finish around openings?
Can openings be added to Fabcon panels in the future?
Are Fabcon panels finished on the inside?
Can the wall panels carry the roof load?
Can electrical conduit be cast-into the wall panel?
What seismic ratings are available?
What other products does Fabcon manufacture?
What soundwall products do you make?
Does Fabcon manufacture traffic barriers?
Does Fabcon do retaining walls?
Is Fabcon a General Contractor?
Who/What is Fabcon?
Answer: Fabcon was first started in 1970 with incorporation in 1971. The first plant location was in Savage, Minnesota. In 1986, Fabcon, Inc. purchased the Span-Deck technology and became the franchise holder. In 1995, Fabcon expanded operations through the acquisition of American Precast Plants near Indianapolis, Indiana and Columbus, Ohio. In 2001, Fabcon built a new, state of the art plant in Mahanoy City, Pennsylvania to service the East Coast market. In 2001 Fabcon developed Versa Core technology.
How long has Fabcon been in business?
Answer: Fabcon was first started in 1970 with incorporation in 1971. The first plant location was in Savage, Minnesota. In 1986, Fabcon, Inc. purchased the Span-Deck technology and became the franchise holder. In 1995, Fabcon expanded operations through the acquisition of American Precast Plants near Indianapolis, Indiana and Columbus, Ohio. In 2001, Fabcon built a new, state of the art plant in Mahanoy City, Pennsylvania to service the East Coast market. In 2001 Fabcon developed Versa Core technology.
What kind of precast does Fabcon make?
Answer: Fabcon specializes in design, manufacture, and installation of structural precast concrete wall panels. These wall panels can be used in either a load bearing or non-load bearing configuration and are available in a variety of R-values as well as finishes.
Fabcon also manufactures other concrete sections such as columns, traffic barriers, soundwalls and retaining wall systems.
What quality assurance programs does Fabcon have?
Answer: Fabcon is a member of PCI (Precast Concrete Institute) and is subject to PCI’s plant certification program. Fabcon is PCI certified producer, an ISO (International Standards Organization) 9001, 2008 certified company and complies with ACI 318. In addition Fabcon’s field crews are PCI Certified Erectors. Please request a “Manufacturing and Installation Guidelines and Guide Specification” from your sales engineer.
Does Fabcon conduct research and Development?
Answer: Yes, as a result of extensive R&D Fabcon has developed many patents and proprietary products over the years. We continue to be a leader in the innovation of building solutions. As part of the R&D efforts there are independently verified tests including flexural bending, 30-year life-cycle testing and shear capacity tests. Tests are conducted for various applications such as large beam loads, mezzanines and roof-bearing conditions.
Where do you produce Fabcon wall panels?
Answer: Fabcon currently has four plant locations: Savage, MN; Grove City, OH; and Mahanoy, PA.
Who designs Fabcon’s panels?
Answer: Fabcon maintains a full Engineering staff responsible for designing the structural performance, including connections, of the wall panels. We interact with other sub-trades engineers as well as the project engineer to ensure our systems interface properly.
What is prestressing
Answer: Prestressing refers to the steel tendons reinforcing in the wall panels. Steel tendons are placed in the form and put in tension (stretched) prior to the concrete being poured. This pretensioning takes advantage of steel’s inherent tensile strength. The concrete is then cast around these pretensioned strands and allowed to cure prior to the strand being released. The result is that the concrete bonds continuous along the strand’s length, holding the steel in tension while the steel holds the concrete in compression. The net resurlt is the synergy of steel and concrete presenting a much stronger cross section then either product is capable independently.
Will Fabcon perform as Engineer of Record?
Answer: No, Fabcon is not the Engineer of Record. Our scope of work is limited to the design and manufacture of the wall panels including the connections. Structural steel, pre-engineered systems, foundations and other structural elements are to be designed by others.
Who erects Fabcon’s product?
Answer: Fabcon has historically erected all of our own products. Our field crews are union members and can work on any job site. While they are Fabcon’s employees, the same people are available to erect product on an open shop job site. Field erection crews are highly experienced and specialized in Fabcon products. Field crew can ensure timely, quality installation of Fabcon products on your job. It also creates one-party responsibility (Fabcon) for the design, fabrication and installation of the wall panels.
Does Fabcon use union field crews?
Answer: Fabcon’s field crews are union (specifically, bricklayers and laborers) and have installed Fabcon products throughout the United States. While our crews are union they will also work on open shop projects.
Does Fabcon make the connections between the precast and the steel?
Answer: If the temporary shore or permanent steel system(s) is used and the structural steel is in place prior to erecting the precast then Fabcon crews will make the welded connections between the steel and precast systems. In the case where the precast is installed first, either Fabcon or the steel erector may make the connections which will be resolved, typically at the time of bidding, pending individual projects requirements.
How long does it take to get Fabcon panels to the jobsite?
Answer: Lead times as defined by Fabcon, typically begin with the receipt of complete architectural and structural drawings. The typical process of creating shop drawings, aquiring approvals, and completing the production process is approximately seven to eight weeks. Lead times can be impacted by work volume, weather, and other factors. However, it may be possible to complete projects in a shorter period of time, depending on the complexity of the project.
Does the steel have to be erected prior to the precast installation?
Answer: With the Fabcon precast system, either the steel or precast can be erected first. In the case where the structural steel is erected prior to precast, this is referred to as a temporary shore system. In the case where the precast is erected prior to the steel, referred to as “freestanding”, wall braces are installed to support the walls until the diaphragm is complete.
What are temporary shores?
Answer: Temporary shores are 8″ x 31′ steel columns furnished by Fabcon to the job site prior to the arrival of the precast wall panels. The temporary shores support a ledger beam, typically a W10 x 17 beam by the use of a friction connection along the bearing walls on which the bar joists are set. Use of the temporary shore system allows for the installation of the structural steel system prior to setting the wall panels. Fabcon then installs the wall panels, makes the welded connections to the ledger beam and/or starter joist and then removes the temporary columns to return to our yard to be used on future projects.
What is friction connection?
Answer: Friction connection consists of a flat plate, a coped angle, and two bolts that are attached to a temporary shore to establish the elevation of the ledger beam. This connection is an adjustable connection relying on friction between the plate and temporary column, hence its name. It is important not to over tighten friction connections as this decreases their capacity.
What is freestanding?
Answer: Freestanding is a term used to describe the wall panels being erected in place on the job site prior to the structural steel being installed. Since the structural steel and deck are not in place to take the diaphragm load from the building, a wall brace is installed diagonally from the wall panel (to either the exterior or interior of the building) to a deadmen to take the construction loads until the steel and deck are completed.
What is a dead man?
Answer: A temporary foundation for a brace. Deadmen can be poured concrete, an at grade mass, a reinforced section of floor slab or most commonly, a helical anchor that Fabcon can “screw” into the ground.
Does Fabcon set the steel and/or pour the footings?
Answer: Fabcon does not set structural steel other than miscellaneous sections which attach to our wall panels. Neither does Fabcon install footings. We only design, manufacture, and install the precast wall panels.
What is a Fabcon’s definition of a keyway?
Answer: A keyway is a trough created in the footing into which the panel is set. The inside edge of the keyway determines the interior building line as panels with standard finish are set tight to the inside edge of the keyway. The depth of the keyway is typically 3″ allowing shim space to adjust the panels to align bands and / or height of openings. The keyway is a minimum 15″ wide for 12″ Versa Core panels and 11″ or 12″ wide for 8″ or 8½” Versa Core panels. Fabcon typically fills the keyway with grout.
Does Fabcon have other footing details?
Answer: Fabcon uses a variety of bearing details on footings, foundations, grade walls, etc. Options include a keyway which allows setting wall panels with a grouted connection eliminating welding. There are also mechanical connections with steel angles and/or plates welded or bolted to accommodate each building design.
Where does Fabcon use grout and what type of grout?
Answer: Typically at a keyed or flat footing connection. When setting on top of a foundation wall Fabcon uses shims in lieu of grout. Fabcon utilizes a standard 3:1 sand/mix grout to fill the keyway / grout space and lock the wall panels in place. This cementious mix fills the shim space between the footing and wall panel and lock in the panel in place from lateral movement. It is not necessary to use a non-shrink grout and is not designed to be waterproof.
Do you caulk Fabcon wall panel joints?
Answer: Fabcon typically will furnish and install the caulk on both interior and exterior joints of the wall panels. Also included in this application is the backer rod (rod stock) to support the caulking. Fabcon uses a two-part urethane caulk from a variety of manufactures to ensure a quality sealant on the job. Fabcon does not including caulk between precast and other materials (doors, windows, block etc).
Are Fabcon wall panels better than block?
Answer: Precast wall panels are superior to block construction in a variety of aspects. During construction precast wall panels can be erected faster and under harsher weather conditions. Precast is capable of handling greater structural loads, and offers greater energy efficiency while reducing long term maintenance costs. Fabcon wall panels are also advantageous in terms of air and moisture infiltration.
How is precast different or similar to site cast?
Answer: Precast and site cast panels are both concrete products and offer advantages over both CMU and metal however there are differences. Fabcon’s precast is manufactured in a controlled environment with highly skilled workers that specialize in the manufacture of precast products. Precast can be manufactured year round with consistent, documented quality. Sitecast is subject to variable weather conditions and restrictive pouring conditions. Sitecast manufacture limits access of other trades to the construction site and often impacts construction schedules. Sitecast requires pouring on the slab and possible damage or use of casting-beds on site which further disrupt the site and add to cost and schedule.
What is Fabcon’s price per square foot (wall surface area)?
Answer: Price per square foot of wall panel varies significantly depending on the type of project, location, finish, and functionality of the panels. While price per square foot may be a useful way to describe the wall panels, it is misleading in that different panels on a project have varying costs depending on the profile of the panel. For example, a single piece located at a non-bearing area of the building will be more economical per square foot than a load-bearing panel with openings in it that may have a different finish. Your sales engineer can explain in greater detail and suggest value-engineering ideas.
Are Fabcon’s Wall Panels sustainable?
Answer: Yes, Concrete in general is a very “green” or sustainable product and Fabcon has taken sustainability to a new level with VersaCore technology which replaces the hollowcores with EPS billets increasing the energy efficiency of the panel while allowing cast-in openings. The evolution continues with Versa Core Plus which further enhanced the energy efficiency and less raw materials through more efficient structural design. VersaCore Plus Green uses higher recycled content while further increasing the energy efficiency making it a contributing component in a projects qualification under LEED.
Compared to conventional composite panel designs, VersaCore Plus Green weighs 32% less than conventional composite panels while offering a 30% increase in R-values.
What is LEED’s?
Answer: LEED stands for “Leadership in Energy and Environmental Design” and is a voluntary Green Buildings Rating system for developing high performance sustainable buildings. LEED addresses all building types and emphasizes state-of-the-art strategies in five areas: sustainable site development, water savings, energy efficiency, materials and resources selection and indoor environmental quality.
How can Fabcon help me qualify for LEED’s certification?
Answer: Various levels of LEED certification are based on a points system. The use of Fabcon’s panels would qualify the building for a specific number of points based on the panel’s recycled material content, energy efficiency and project location in relation to the location of the raw materials supplied on the specific building.
What are Fabcon’s R-Values?
Answer: R-Value refers to the resistance of a material to transfer heat. While R-Values are commonly used in reference to building materials they are not the most accurate way to determine the energy efficiency of your building. Fabcon has a brochure available which explains how to legitimately evaluate how efficient your structure is. R-Values will vary with degree-days, please review information on R-Values.
What are Fabcon’s R-Values?
Answer: VersaCore Plus Green builds on the success of the castilated web design of VersaCore Plus which is similar in concept to the steel industry. Fabcon determined that the webs, which are concrete “columns”, are redundant in their structure and by removing concrete in specific areas (called drop-ins) reduce material without compromising structural performance. Each project and in fact each panel, is designed to meet the specific requirements of your project, there is no set pattern of drop-ins.
The result is an increase in the amount of face area that is insulated resulting in higher R-values. Also, the removal of concrete allows for the reduction in weight saving on freight and handling costs.
How thick are Fabcon’s wall panels?
Answer: Panel thicknesses are available from 8″ to 12″ in thickness depending on product type, finish and amount of insulation. The 8″ Versa Core Plus Green wall panel incorporates the billet technology creating the core in the panel. The cross section contains structural webs of concrete, which are continuous from the outside to interior surface. The 12″ Versa Core Plus Green insulated sandwich panel uses the same 8″ Versa Core structural section but adds 2½” of continuous insulation and a 1½” finish façade. The advantage of the 12″ insulated panel is the continuous insulation and isolation of the structure from thermal affects.
How wide are Fabcon’s panels?
Answer: Fabcon precast wall panels are available in widths up to 11′–11½” from the MN, OH and IN plants; and panels up to 13′–5½” are available in the PA plant. Majority of the volume is 7′–11½” width to most efficiently take advantage of freight. All panels width are designed to accommodate a ½” caulk joint resulting in an actual center-to-center dimension of 12′, 13–6″ and 8′–0″ respectively.
What are the narrowest width panels for mitered corners, for partials to support headers, for typical bearing or lap condition?
Answer: Minimum widths are determined by the structural design. It’s recommended to maintain a minimum 30″ width for the precast section to contain 2 sets of strands; more strand may be necessary as the height increases.
How tall are Fabcon’s wall panels?
Answer: Fabcon has designed, manufactured, and installed wall panels more than 62 (varies from plant to plant) in length as a load bearing unit. For multi-story structures, we have erected sixteen (16) stories, all precast, load bearing structures. This is a unique advantage to Fabcon’s system of being able to go to greater heights carry greater loads than competitive systems.
Are Fabcon products structural or architectural?
Answer: Fabcon designs, manufactures, and installs a structural wall panels under both designations. The structural wall panels offer a variety of decorative finishes that rival architectural panels. Under the guidelines of the PCI (Precast Concrete Institute) this is referred to as MNL 116. However, Fabcon also produces wall panel under PCI’s designation of MNL 117, architectural precast. Consult your sales engineer to determine which delivers the best value for your project.
What kinds of Finishes does Fabcon’s offer?
Answer: Fabcon manufactures a wide variety of textures (rakes, ribs, imprint, flat, etc..) including both extruded and formside finishes with formliners. Exposed aggregates finishes can be accomplished as water-washed, formside exposed and different levels of sandblasting. Local and specialty aggregates are available on standard width (8′) and special widths (up to 12′ in MN & OH and 13′-6″ in PA). See our online Finish Guide and/or web site.
A unique and popular finish is to cast brick into the precast wall panels. By casting brick into precast concrete wall panels you eliminate the masonry grout of traditional brick construction. This eliminates “tuck-pointing” maintenance issues for the life of the building and also eliminates the environmental impact and site disruption of brick construction. Cast-in brick is done with liners on the steel formside of the panels. Cast-in brick is available in several materials. Traditional clay fired, concrete from various suppliers and a 100% recycled brick by VAST Manufacturing.
What imprint patterns are available?
Answer: Fabcon’s top finish process allows different imprint patterns applied to the exterior face. Patterns that simulate brick and/or block patterns are available however the flexibility extends to custom finishes that maximize the advantages of precast. Imprint patterns include 4″ x 8″ with a 1/2 running bond, 4″ x 12″ with a ⅓ running bond, 4″ x 16″ with a ½ running bond, 8″ x 8″ stack bond, 8″ x 16″ with a ½ running bond, and 16″ x 16″ stack bond. Also available are 4″ on-center and 8″ on-center horizontal imprint lines.
Please consult your Fabcon sales contact for more information.
What are our minimum and maximum band widths?
Answer: On a smooth (form side) finish the minimum band width is 1.5″ and the maximum depth is ½”. On top surface finishes the minimum width is 4″. Band widths over 3′–11½” on the form side require splicing form material which may display a line in the finish. Top finish band width in excess of 4′ are prone to more variation in texture.
What angle can the edges of the reveal be?
Answer: Typically the shoulder for a cast-in angle is 45 degrees although 60 and 30 degrees are available. 90 degrees is not recommended due to the spalling that occurs when removing the band material.
What colors are available in the wall panels?
Answer: Standard finish on the wall panels is a natural gray concrete which will vary in color due to a variety of factors. Fabcon strongly recommends that they be painted or stained for aesthetic purposes. This application is not required to seal or protect the panels from air or moisture infiltration nor is it included in Fabcon’s scope of work.
The exposed aggregate and sandblasted panels are available in a variety of aggregates, typically local to each plant location. The matrix of exposed aggregate finishes will be tinted to compliment the natural color of the rock. The owner may select a different tint if so desired. Exotic aggregates can be shipped in from non-traditional sources at additional costs. However, aggregates not previously approved must be tested for compatibility and long term viability, this testing may impact the project lead-times. White cement is another color option for expose aggregate and sandblasted finishes.
What colors are available in the wall panels?
Answer: Custom finishes are available from Fabcon including sandblasting and acid etch. There are limitations to these finishes, please consult your sales engineer. Both finishes are available on the structural formside surface of the wall panels.
What is Fabcon’s finish around openings?
Answer: Fabcon will either cast in an opening or saw an opening depending on the application for the wall panel. Edges will be a minimum of 3″ of solid concrete; in the cases of a cast in opening the edge surface is rougher in nature and may require some finishing. In the cases of sawn openings, edges will be a sawn, smooth surface.
Can Openings be added to Fabcon panels in the future?
Answer: Fabcon requires notification prior to cutting new openings in existing buildings. If necessary, connections are added (either bolted or “mudded” in) to the adjacent panels to redistribute the load across the wall panels. The field crew will verify the location of drop-ins (insulation) and determine the most effective location for new connections.
Single pedestrian door openings (3′–4″ wide) and window openings that are less than 4′–8″ wide can usually be sawn into the center of full width panels without additional connections to adjacent panels but should be verified with Fabcon’s engineering department.
Can Openings be added to Fabcon panels in the future?
Answer: When the exterior finish is specified as ribs, rakes, water-washed exposed aggregate, imprints, etc., the interior building finish is the steel form side of the panel. However, when the steel form, smooth surface is turned to the exterior the interior finish can be a broom texture or a troweled finishes. In either case the steel form surface is high-density concrete and may contain small pit holes, which may require patching prior to finishing.
Can the wall panels carry the roof load?
Answer: Fabcon wall panels are designed to be load bearing and are most efficient in that capacity. The wall panels can take dead-loads as well as shear loads; Fabcon has engineers on staff to answer specific loading questions. These load-bearing panels can and have been used as cladding only.
Can the wall panels carry the roof load?
Answer: Yes, there are two methods of placing electrical in Fabcon’s wall panels system. First, boxes and conduit can be cast into the wall panels during production. There are special considerations so talk with your sales engineer. Secondly, special billets that contain an open chase can be cast into the panels easily with nominal cost. This chase runs vertically in the panels, or horizontally in the case of spandrel panels, in one or all six billets. Electrical can be run from the top of the wall panel or cut in above the ceiling elevation to allow electrical lines to be dropped to the appropriate elevation and electrical boxes mounted flush in the wall. Openings for electrical boxes would be field cut into the panels by others. This system allows the greatest future flexibility for electrical work.
Are fire ratings available?
Answer: Yes, PCI (Precast Concrete Institute) outlines calculations to determine various fire protection levels and VersaCore Plus Green can be modified for “solid” areas to meet Fire Manual requirements for fire ratings up to four hours. Note that special treatment (fire stop material) of panel to panel joints is required for ratings beyond 1 (one) hour.
What seismic ratings are available?
Answer: Seismic Design is a complex issue and is site specific; your engineer of record will need to determine the classification of your site. “B” and “C” ratings can be accomplished with the wall panels with additional reinforcing and connections. Seismic “D” is also available, however, the engineering and manufacturing changes are more substantial; and panels need special reinforcing “grids” which need additional lead-times. In most case the panels need to be solid concrete which reduces energy efficiency and increases costs.
What other products does Fabcon Manufacture?
Answer: Fabcon manufactures a number of precast products including sound walls, retaining walls and blocks as well as traffic barrier and soundwall posts. Fabcon’s R&D are continually testing new products in addition to the improvements in our existing lines.
What other products does Fabcon Manufacture?
Answer: Fabcon manufactures Sentry Cast reflective sound walls utilizing a vertical casting system which allows finishes on both faces of the panels as well as wrapping the finish on the columns. Sound walls are available in a variety of textures simulating stone and masonry walls. This system offers the speed, efficiency and durability of precast at more competitive prices than natural stone walls.
Does Fabcon manufacture traffic barriers?
Answer: Fabcon manufactures various traffic barrier products. Each states DOT (Department of Transportation) have unique designs however, not all projects (private developments, power companies, municipalities, prisons etc) want or need DOT specification products. Custom barriers are available upon request please consult your sales engineer for lead-times and pricing.
Currently Fabcon manufactures traffic barriers for Ohio (Design RM 4.2), Minnesota (MNDOT 8337B), Missouri (Design 617.20 C), Iowa (IADOT BA-401), Wisconsin (WIDOT 14B7), West Virginia (Design GR13), South Dakota (Design 628.01).
Does Fabcon manufacture traffic barriers?
Answer: Yes, Fabcon manufactures two different systems for retaining walls; one is a modular system and the other is a column and panel system.
Sentry-Cast Block is a modular system that can incorporate geo-grid systems and offers a unique solution to the hydrostatic pressure and weight issues of traditional retaining wall systems.
Fabcon adapted a vertical (battery forms) casting system allowing textured finishes on both faces. Sentry Cast is a system that incorporates the wall panels with columns offering a unique solution for precast fencing, retaining walls, privacy walls, security applications or sound walls. Sentry Cast walls offer authentic appearance of stone or masonry walls with the installation, durability and cost advantages of precast.
Is Fabcon a General Contractor?
Answer: Fabcon is not a General Contractor and typically subcontracts to General Contractors. We will also work directly with Owners who are acting as their own General Contractor or wish to use a Construction Manager to coordinate their work.