CarbonCast

CarbonCast is a precast concrete technology
that uses carbon-fiber grid as secondary
reinforcing or as a shear truss. It was introduced
by AltusGroup, Inc. , a national partnership of
14 precast concrete manufacturers and seven
industry suppliers founded to expedite the
research and national commercialization of
concrete innovations.
Products
The CarbonCast line of products includes:
CarbonCast High Performance Insulated
Wall Panels are composed of two concrete
wythes separated by continuous insulation and
connected by C-GRID carbon fiber shear
trusses [1][2]
CarbonCast Insulated Architectural
Cladding feature inner and outer wythes
1-3⁄4″thick or more for a total concrete
thickness of 3-1⁄2″. The wythes sandwich a
layer of insulation of usually 2″ or more
depending on R-value requirements [3]
CarbonCast Architectural Cladding employs
a steel reinforced Vierendeel-like truss frame
attached to a thin, C-GRID reinforced
diaphragm face. Insulating foam forms around
patented V-ribs, designed to create a thermal
break with the face of the panel, and displaces
concrete to provide insulation while C-GRID
carbon fiber shear trusses mechanically link
the face and truss ribs[4][5]
CarbonCast Double Tees replace
conventional steel mesh reinforcing in the
flange with C-GRID carbon fiber grid [6]
Properties
The use of carbon fiber grid over conventional
reinforcement yields a number of unique
properties to CarbonCast components: [7]
Lower weight - When carbon fiber grid
replaces steel mesh in the face of concrete
products, manufacturers can use less concrete
cover to protect the mesh from corrosive
elements. Non-corrosive carbon fiber
eliminates the need for extra concrete
Improved thermal performance - The
relatively low thermal conductivity of carbon
fiber permits CarbonCast components to
provide higher R-values than conventional
precast concrete
Improved strength - Carbon fiber is four times
stronger than steel by weight providing better
surface crack control when used as secondary
reinforcing and 100% composite action when
used as a truss in insulated wall panel
Comparable cost - Many applications receive
savings in foundation and super structure
(reduced weight), energy costs (insulation) and
maintenance (reduced corrosion)
Applications
There are more than 300 projects totaling more
than 17,000,000 square feet (1,600,000 m 2 )
of surface area of CarbonCast technology in
these markets:
Education
Industrial/Warehouse
Commercial Office
Parking Structure
Multi-Family Residential
Retail
Examples
Prominent structures that have used CarbonCast
technology include:
Proximity Hotel , Greensboro, NC
Lucas Oil Stadium , Indianapolis, IN
University Commons at Georgia State
University , Atlanta, GA