
Concrete Benefits of Building a Concrete Home
The article details the advantages of constructing a residential property using precast concrete panels, as exemplified by Ed and Meg Faichtyger's experience in Franklin Township, New Jersey. The Faichtygers transitioned from a small apartment to a 1,940-square-foot, two-story home, achieving a 30 percent reduction in their monthly electric and gas bills through the use of concrete construction. They opted for Xi Walls and the Prespan flooring system from Northeast Precast, which are custom-made with insulation to provide a dry and comfortable living environment. The precast concrete structure for their new home was installed in just two working days, with the house being under roof in less than two weeks.
Ed Faichyger highlighted the energy efficiency and quietness of their concrete home, attributing it to the solid nature of the walls that prevent air and noise infiltration. He noted that the cost difference between wood and concrete homes was minimal, but the long-term benefits of concrete, such as resistance to water damage, rot, and fire, significantly reduce maintenance concerns and lower homeowners' insurance premiums. The design, by J.W. Pedersen Architect, P.C., incorporates a three-bedroom layout with 1,940 square feet of living space, a 1,232-square-foot basement, and a 700-square-foot two-car garage.
A key design feature is the open floor plan, facilitated by the precast concrete planks that span the width of the house without requiring beams or support columns. This eliminates issues like creaking or bouncing often associated with traditional flooring. The home's insulation is so effective that internal occupants are largely unaware of external weather conditions. The patented Prespan flooring system, used in the Faichtyger home, utilizes insulated precast floor planks suitable for both residential and commercial applications, eliminating the need for interior structural supports and providing open spaces.
Mark Gorgas, commercial division general manager for Northeast Precast, explained that the Prespan system allows for a clear span of the entire building, enabling the creation of full basements or crawl spaces under garages. This rigid product is 25 percent lighter than hollow core planks and offers less deflection. The integrated EPS foam within the precast floor system effectively reduces sound transmission between floors, further enhancing the home's comfort. The Xi Wall system, used for the foundation and exterior walls, significantly saved time and money during construction. These custom-manufactured precast panels are produced off-site in indoor facilities, preventing on-site soil contamination and eliminating the need for on-site sprays or bituminous coatings for dampproofing.
Certified crews install the precast wall panels directly at the job site. Superior Walls products, engineered with insulated concrete studs, minimize the use of materials like wood and concrete, thereby reducing the carbon footprint of construction. For the Faichtyger home, the thermal mass of concrete lightened the load on their HVAC system and maintained consistent indoor temperatures, allowing for a reduction from two air conditioning units to one. Stucco and stone were applied directly to the precast panels, and the wall assembly achieved an R-Value of 31.5, with the Prespan flooring reaching R39. The reinforced concrete walls were able to transform a problematic gable wall with windows into a shear wall, and combined with the rigid floor system, the structure effectively resists lateral wind loads. The Faichtygers found the total cost of precast concrete to be about a quarter of their project cost, noting savings in construction time and daily energy expenses, leading them to recommend precast concrete construction to others.
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