Exterior Wall Options for High Bay Warehouse?

[Guastavino]

Other than tilt-up, what options have you guys used for high bay warehouse exterior walls? Client wants 36' clear, so likely 40' total height exterior walls. Might need Brick finish, PEMB won't work at this location because it needs to look nice. Any other creative solutions other than tilt-up that you all have seen used? To me, this seems tilt-up or bust. Maybe offsite made precast wall panels? SE U.S. is location.

 

[XR250]

I think you are in my area of the Triangle.
These guys (

http://www.metromont.com)

make pre-cast wall panels. Might work for you application. You could also do a steel frame with a a few girts and metal studs.

 

[Guastavino]

XR, thanks much, yea I'm not far from there. And thanks for the metromont reminder. I was thinking Tindall, but forgot about Metromont. Tindall's website didn't have enough for me to determine their wall height capabilities. I'll put a call into metromont and see what they can do. I'd prefer to avoid tilt-up, as it's a smaller building ~21,000 square feet or so, and it just doesn't seem economical on something that small. Panels seem a better option if they can make them that tall economically, and I would guess that they can.

 

[Retrograde]

Alpolic (aluminum composite) cladding?

 

[thaidavid40]

Insulated structural metal panels? Some of these even have patterns (like brick) embossed on them for a better aesthetic effect. However, consider whether or not the inner face of these will be protected against warehouse activities, as they could end up looking terrible inside if they are exposed to knocks and dings.
Dave

Thaidavid

 

[sbisteel]

Canam makes a prefab steel insulated metal panel system, check out Murox panels on their website. This won't work with the brick finish however.

 

[MotorCity]

Before I read your post, I instantly thought tilt-up/precast. For similar projects we have used CMU (although the 36' height may be pushing the limits) or use a girt and siding or insulated panel system

 

[JAE]

Like thaidavid40, we have used insulated metal panels.
Here's a link to one manufacturer:

http://www.metlspan.com/

This requires horizontal girts between columns to attach the panels to. Typically about 12 ft. o.c. vertical spacing unless you are near the coast - then perhaps 4 to 8 ft. spacing depending on the panel type and thickness.

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[XR250]

Panels seem a better option if they can make them that tall economically, and I would guess that they can.

Precision Walls in Raleigh used to do metal stud panelized systems with aluminum composite cladding. don't know if they still do.
They also used to do them with thin brick veneer.

 

[JAE]

I meant to add that the metal panels we used extended up to peak roof heights of about 40 ft.

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[Guastavino]

JAE, do you know cost-wise? I'm guessing that the metal panels (if they look nice) would be a lot more than precast panels in terms of pricing?

Cheaper looking wall panels won't work at the site since it's a nicer business park that likely won't allow an eye sore.

I'm leaning towards attempting precast wall panels, but very happy to learn of these other options for the future

 

[JedClampett]

It seems as if you have three choices:
CMU-Hard to span vertically that distance. Twelve inch blocks are pretty labor intensive.
Cast in Place or Tilt-Up Concrete-Probably the easiest to design and construct, especially plant cast.
Some kind of Metal Siding-Probably more work for you, detailing girts and sag rods, but very feasible. I don't think it's all that much of a price difference from tilt up.
One thing that's driving our designs more and more is energy code considerations. If the warehouse is not conditioned, it's not a big deal (except for the guys and gals in there sweltering), but if it's cooled or heated, you need a minimum wall "R" value. Ten inches of concrete gives you an R of .75. That's unlikely to be enough to meet any code requirement. So you're either going to have to go with sandwich panels or add insulation on the outside (EIFS) or inside (furred walls with insulation panels in them). Of course metal panels provide no insulation value, unless they're made with a foam layer. CMU can have interior insulation or the options above.

 

[Guastavino]

A/C isn't too important to them, so that's good. I see it likely ending up as precast panels. Metal siding won't be accepted unless it looks really nice, and then that will cost a fortune.

 

[JAE]

I think the precast and/or tilt up would be more expensive than the metal panels by far.

As far as aesthetics go - I've seen where a lower, concrete, block, or brick system is used in the bottom 12 ft. of the wall and the upper part is a metal panel.
That requires the lower wall to either cantilever up off the footing or some type of horizontal girt beam provided to brace the top of the wall yet accommodate the steel frame movements.

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[theonlynamenottaken]

I've used precast sandwich wall panels with rigid insulation board core for tall walls, but I'm fairly certain that 40' height is out of range without some girt or floor diaphragm between roof and floor. At that height you'd probably be looking at double-tees of you want clear-spanning precast concrete, and you'd have to set the stems to the interior for a brick façade.

I'd really like to hear if you find that precast solid, hollow-core, or sandwich panels work out for this application.