08-01-04 | News

Modular Concrete Wall Systems imitate Wood and Stone

By Leslie McGuire, regional editor

Modular wall systems using interlocking panels and posts made of high-performance glass fiber and steel-reinforced precolored concrete look like natural wood, stone or lattice, but have the ability to withstand wind, soil and thermal movements.

 

Producers of decorative precast concrete fences and screening walls have seen a spike in business nationally. That’s because these innovative modular systems are being used more and more at residential developments, commercial and industrial properties, water-storage facilities, electrical substations, waste-treatment centers and other utility and government projects.

Many municipal buildings and utilities simply need better options for screening walls, perimeter walls and sound barriers, to enhance both their security and privacy. But more and more, they are forced to face tougher code requirements spiraling costs and the aesthetic concerns of neighbors.

Many are also faced with the realization that the old standards they’re using to protect the perimeter of their existing or planned facilities, such as the chain link fence and traditional masonry, may no longer suffice. So they’re looking for something more substantial and cost-effective. However, they’re doing so at a time when faced with stricter building codes, escalating costs, growing neighborhood concerns and some of the worst budget constraints in decades. Increasingly, Superior Concrete Products of Dallas-Fort Worth is reaching out to meet this more demanding market with a distinctive concrete-fence product that is literally rock solid.

Custom color and finishing combinations make it possible to match virtually any existing wall, architectural style or aesthetic considerations. Painting and highlighting grout lines can further enhance the project.

“Precast concrete walls, which are made of steel-reinforced, high-strength concrete, can be integrally blended to match surroundings, and are attractive, cost-effective and provide maximum security,” said Barry Stevens, vice president of sales and engineering. “They can be customized, tailored to different heights, and cost as little as half that of masonry, depending on several variables.”

These precast walls need no regular maintenance, and unlike masonry, which requires a continuous foundation, the piers are set at five-foot intervals and can be strategically situated to easily straddle utility lines without severing them. The five-foot intervals also make them very difficult to penetrate. “We have never seen a vehicle go through one of our walls, even along a busy highway,” said Stevens.

The pier size, depth and reinforcement is constructed as specified within site specific engineering drawings. After the posts are accurately spaced, plumbed and leveled, they are braced until the pier concrete has obtained its initial strength.

Aside from creating secure and neighborhood-friendly fences, these are designed to blend into their environment and integrate with masonry, stone or wood elements. When the city of Irving’s new city building code was enacted in 1999, a chain link fence surrounding the city’s Texas Service Center, which houses city vehicles and equipment, was suddenly out of compliance. So, the city ordered a precast concrete fence from Superior, which was able to match it to the color of the service center.

In the past two years, security has become a more acute concern for government facilities, utility companies and businesse. Managers of such intrusion-sensitive operations are scrambling to protect their power plants, water plants and city and commercial buildings. Of course, intrusions are nothing new to utilities and public-works departments, which experience thousands of illegal entries each year, ranging from pranks to vandalism to theft, and even eco-sabotage.

Many Uses

These fence systems are excellent for municipal facilities, utilities and road projects. They are well suited for secure perimeter fencing and screening walls around intrusion-sensitive facilities. Residential developments find the natural look improves property appearance and security while meeting masonry requirements and conforming to or exceeding local codes. When used at commercial and industrial properties they provide a “neighbor-friendly” buffer between residential areas and commercial/industrial properties while providing additional curb appeal and security for its users. They should not, however be used alone as a retaining wall for the support of soils or other structural elements.

Speedy Installation

One crew can install up to 100 feet per day for a six-foot fence and up to 75 feet for an eight-foot fence with no heavy equipment necessary.The posts are positioned and erected by site-casting the column or post into a drilled pier. With the new posts erected, the panels are manually slid into place. Where post spacing must be less than five feet, the panels are sawed to the length required to fit, then the post caps and panel caps are bonded into place by applying a silicone-based adhesive.

Very Low Maintenance

Pre-cast walls generally look as good after 10 years as they do after 10 days. They need no painting, will not burn, split or warp, are designed not to crack or shift with ground movement, and are impervious to termites and easily repaired if damaged by collision. Where excessive dust and dirt are prevalent they can be occasionally washed down.