[Altavia]

Originally Posted by BrianL99

I had no clue The Villages were now using precast concrete for home construction.

#1 drawback in my opinion (I only do commercial construction now), is there's little or no flexibility, once the structure is done. You can't change much of anything and even something as simple as running a cable for your TV, can become a huge job. Everything that runs through the house, is run through a conduit in the walls ... anything you add, has to go on the wall.

They use reflective foam insulation panels and furring strips on exterior walls making space for wiring.

It's reported they also no longer do design modifications to exterior walls other than a few standard bumps. Even on stick and CB homes.

[rogerk]

No downside! Precast concrete is stronger and your home will be more energy efficient than concrete block or a frame (stick built) home!

[bark4me]

I'm surprised they only use reflective foam. I figured since precast does not have the depth and dead air space like block, that they would use 2x4s with standard insulation. Hummmm

[MandoMan]

Originally Posted by djlnc

Aside from possible limited design options, is anyone aware of any drawbacks to the use of the precast walls they are now using for homes here?

You are referring to the Superior Wall System, made throughout the country. They’ve been used for long time for basements. I had a house built with no basement and Superior Walls for the first floor around 1990. So far as I know, mine was the first residential home to do that. It’s a wonderful system if you have a slab floor.

The system is made in a factory on huge tables out of 6,000 psi concrete—which is much stronger than a poured-in-place wall. They have built in 1” styrofoam blue board insulation.

Here’s what happens. First, 2x6 or 2x8 studs are made (hundreds at a time, in molds) by first laying down a 1x2 pressure treated nailing strip with steel attachments driven through it. Then re-bar is placed in the mold, then concrete is poured in and left until it dries a bit. Once this step is done, it’s time for step two. These studs are placed in giant molds on flat tables, styrofoam is secured on top of it, then 2” of 6,000 psi concrete mix is poured over that. It also runs into 8” troughs at the top and bottom, forming the the top and bottom plates and interlocking with the concrete studs, which are on 16” centers. (Before the pour, window boxes and door boxes made of pressure treated lumber are placed where the window and door openings go. While it is possible to add a window later, or change the size, it involves cutting the opening with a concrete saw—a long and dusty mess. Get it right the first time!) The concrete that will be vertical eventually is poured horizontally and very accurately. Before it has set, it is raked with a tool that will help stucco key into it. This is the best stucco backer you can get—much better than steel mesh. The panels are usually between 4’ and 12’ wide and have steel fasteners attached that let them be picked up with a crane and webs.

A couple days later, the walls arrive on a big truck, standing up, and a crane sets them in place on a level bed of sand or gravel. The wall sections are bolted together top and bottom. (Before the panels are set in place, beads of adhesive that never hardens are run along the sides to prevent air and water infiltration. A pressure treated wood top plate adds stability. Then the slab is poured and runs in around the bottom plate of the walls and keys with the studs. This locks everything together and makes the complete system stronger than poured concrete walls, as the connection to the floor is much stronger. The wood nailing strips on each stud are used for attaching the drywall. The window openings with their pressure treated wood boxes are ready for windows at once. The studs have holes every foot or two for running wires. The cavities between the studs are filled with insulation. It’s a wonderful system. That heavy concrete really blocks the noise from outside. Use a tinted stucco and don’t ever paint it. It should be good for generations.

Below is a photo of my old house in Pennsylvania. The whole first floor is Superior Wall Panels. Note all the windows.

[PoolBrews]

Originally Posted by Calisport

One negative is if you want to add a door where there is a window that probably can't be done. Like a window changed to a door out to a new birdcage.

Yes you can. I've seen it done, and may get our bedroom window changed to a sliding door to our pool. They simply cut the concrete out and install the new door. (We have fully poured walls.)

[Altavia]

Originally Posted by MandoMan

You are referring to the Superior Wall System, made throughout the country.

Interesting but not used on The Villages.

https://youtu.be/6dCUekKv-SI

[

[DAVES]

Originally Posted by djlnc

Are you claiming that a stick built house is as strong as one with poured concrete or cast concrete walls?

HUH? Check the punctuation and the caps in the original post. Interesting that they have been altered creating the confusion.

[BrianL99]

Originally Posted by dewilson58

Simple..............Ceiling, cut a groove on the inside wall (then cover) or run on outside of wall.

Not so simple.

The Pre-Cast is structural. If you cut it, the entire structure is compromised. Yes, even if you only cut it 1/2" deep.

50% of the time, you'll hit the wire mesh, that provides some of the integrity of the panel.

[BrianL99]

Originally Posted by PoolBrews

Yes you can. I've seen it done, and may get our bedroom window changed to a sliding door to our pool. They simply cut the concrete out and install the new door. (We have fully poured walls.)

That's simply ridiculous. "They" may do it, but they are idiots.

You can't simply "cut the concrete out" and change a window to a door. I guess you could physically do it, but your house may fall down.

[djlnc]

Interesting responses. I was aware of the limitations in making alterations, but was curious if there were any issues with joints in walls or corners...that sort of thing. It appears that the cast walls are generally a good deal.

[DaleDivine]

Originally Posted by DAVES

HUH? Check the punctuation and the caps in the original post. Interesting that they have been altered creating the confusion.

If, you'll notice, OP did an edit and went back and punctuated after the word "NO" and added a word.....

[DaleDivine]

Originally Posted by BrianL99

I had no clue The Villages were now using precast concrete for home construction.

#1 drawback in my opinion (I only do commercial construction now), is there's little or no flexibility, once the structure is done. You can't change much of anything and even something as simple as running a cable for your TV, can become a huge job. Everything that runs through the house, is run through a conduit in the walls ... anything you add, has to go on the wall.

The other potential issue I suspect, is that each pre-fab panel is probably a structural unit and necessary for the integrity of the home. That means, you can't just enlarge an area or change an interior dimension or wall.

Again, I don't do this for a living and have only done commercial versions, so I could be all wrong here and they have some new techniques, which allow precast to be practical in a residential environment.

There is no question that panelized construction, done inside a factory, can generally produce much higher quality and better tolerances, than site-built products.

Cable company didn't have any problems drilling a hole through our precast concrete wall in our CYV...

[dewilson58]

Originally Posted by BrianL99

Not so simple.

The Pre-Cast is structural. If you cut it, the entire structure is compromised. Yes, even if you only cut it 1/2" deep.

[coffeebean]

Originally Posted by seecapecod

Great points about some lack of flexibility- I’d also add that panelized construction is faster and with new home construction, it’s all about churn!

Is this construction with pre-cast concrete walls less expensive than the conventional type of construction?

[coffeebean]

Originally Posted by bark4me

I'm surprised they only use reflective foam. I figured since precast does not have the depth and dead air space like block, that they would use 2x4s with standard insulation. Hummmm

Are the homes quieter on the interior with the pre-cast concrete block. Sounds very interesting.