Panel Wall – Instant Stone Effect Walling Systems

Superior Build Quality · Cost Saving · Decorative Walling · Natural Stone Effect · Kind to the Environment · Increasing Property Value · Rapid Installation · Aiding Security · Increasing Installation Safety

The Housebuilder Product Awards 2015 finalists have been released and we are proud to announce that Carlow Precasts Panel Wall System is a finalist for the best external product category.

It’s the perfect decorative wall solution for any residential or commercial development, whether an entrance feature, a complete scheme boundary, large-scale roadside perimeter or sound attenuation project.

This rapid install precast walling systems double-sided natural stone look and texture is perfectly designed to blend in with typical UK housing landscapes.

Visually appealing

Keeping in mind that our walling system is designed to replace traditional wall construction we have made it stylish yet robust, hard wearing, with the look and texture of natural stone. It is designed to be flexible, adapting to the architectural needs of the project and is available in various height, layout, terrain and plan configurations.

The realistic masonry pattern is moulded from actual stone masonry construction using polyurethane rubber techniques replicating the exact texture and detail of the stone surface and grain of the mortar. It provides consistency and detail in large scale wall projects that no other product can match.

Many residential developments use a combination of solid panel with railing to provide a more open boundary. This option is particularly suitable for decorative landscaping applications.

The solid wall option is the ideal solution for secure boundary walls, offering visual and access protection yet providing a tasteful traditional wall effect on both sides that will last the life of the structure.

The deep surface texture has proven relatively unattractive to the graffiti artist, who much prefers a plain finish for their artwork.

The naturally articulating assembly easily accommodates thermal expansion and normal settlements resulting a completely crack free structure in service.

Accommodating gate and access openings is easy and the wall panel rebate is ideal for integrating a post for mounting wooden or steel gates.

Rapid installation

The rapid installation process allows huge construction time benefits with substantial cost savings. An installation team of three personnel using a mini-digger can comfortably prepare the ground work for up to 100m of walling on day one of a project.

The footings are isolated at the pier positions and are transverse to the wall line providing greater stability than a conventional strip footing at less cost with less material to be removed from site. In very poor or reactive ground conditions the piers can be placed on small bored piles typically 1.2m deep and 600mm diameter for complete reliability.

The pier and panel units are inherently stable in the temporary condition. The day following placement of the pads the same installation crew can install up to 100m of pillars and panels in half a day! A small amount of concrete poured into the pier void engages the footing starter reinforcement ensuring long term resistance to impact or extreme wind loading.

On larger projects a second team can be used to increase productivity. Some roadside installations to date have exceeded 2 miles in length.

Carlow Precast offer a ‘supply and install’ or ‘supply only’ service. If a supply only service is requested we provide an installation guide and telephone customer support. The installation process is extremely simple and well within the capabilities of a variety or trades already on your site. Add value by increasing the revenue opportunities of your concrete workers, ground workers, carpenters and general operatives.

Variety of sizes

The wall panels and columns are available in heights from 0.6m to 2.5m. However, subject to engineering design they can be stacked to heights in excess of 5.0m. Short panels can be manufactured to adapt to specific site constraints. The typical component sizes are selected to maximize installation rates with conventional site plant while providing a scale of panel and pillar that feels normal in context.

Seamless finish

During the manufacturing of our concrete panels the stacker system stands upright. By pouring self compacting concrete into vertical forms we are able to create precast components which are finely patterned on both sides with very realistic detail. In addition, the vertical orientation of forms allows the concrete to compact more efficiently providing a more attractive and structurally sound product.

Environmentally Friendly

To keep our carbon cost low we currently manufacture with 40% GGBS concrete mixes. With our hot-water concrete production and mix development we aim to increase that further.

Our transverse footing arrangement uses less concrete and generates less site traffic than a conventional approach.

The units are delivered on transport trestles and offloaded into their final position. There are no pallets or packaging to be disposed of.

Safe

With fewer people on site for less time and (in typical lower applications) no working at height, the risks to health and safety are greatly reduced.

Units are delivered with certified lifting loops installed and after a simple visual and twist tightness check two lifting chains are attached for offloading and positioning. The lifting loops are returned then re-inspected and certified for future use.

Cost effective

Due to dramatically less labor and equipment requirements, faster installation, reduced material storage, long life and zero maintenance, the PANEL WALL Precast Walling System is the best value high quality natural stone effect offering on the market. Correctly evaluated, the procurement cost of our system beats that of other apparently cheaper alternatives.

DAY 1

A small team of installers can prepare foundation for 100m in under 5 hours

DAY 2

After 24 hours the area is ready for installation of the pillars and walling. This process will take approximately 3 hours to install up to 100m per day.

Robust

Each robust, hard wearing precast component is steel reinforced providing a 100 year + design life and is tough enough resist denting, corrosion or fading from UV damage, harsh weather and seasonal climate changes.

Naturally Weathering

The units are normally delivered in a natural concrete finish, whitened by a high crushed-limestone content. Accumulating fine natural deposits over time the surface supports the growth of those organisms that also occur on natural stone walls. In time the natural stone appearance is significantly enhanced in colour and texture making it very difficult to differentiate at standard viewing distances. However, the initial white concrete look adds to the new home feel of the development adding to the overall appeal to the prospective homeowner.

Variety of usage…

Retaining Walls

Carlow Precast can manufacture a retaining wall version to your requirements, including a design for stability, footings and reinforcement . The assembly can then be used to retain as much as 2.0m of earth relatively easily. Our concrete panels are engineered to provide the strength and durability to match any similar size retaining wall. The result is a continuous flow of texture and material without the apparent inconsistency of a traditional retaining wall construction and at lower cost.

Privacy Fencing

An attractive and affordable stone privacy wall used to be a compromise. The expense of bespoke masonry can be prohibitive, while affordable alternatives like vinyl, wood, or chain link don’t deliver the durability or look desired.

Public Utilities

PANEL WALL Precast walls add cost-effective long-term value to a public expenditure. Our walling systems are the ideal solution for high volume perimeter walling for electrical substations, water treatment plants, sewage treatment and other facilities. The safety benefits, durability, and aesthetics of the property’s perimeter will be enhanced and secured for a lifetime with zero maintenance.