Non-Traditional Structural Materials Are Gaining Favor Among Forward-Thinking BuildersConsider the Alternatives

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Low- and mid-rise multifamily housing, attached townhomes, and small-scale subdivisions of similarly styled single-family homes are likely to be where precast finds its niche. "If you are building 10 homes on the same block, it makes more sense," says Brian Bock, vice president of sales and marketing for Dukane Precast in Naperville, Ill., a scenario that amortizes the cost of the panels and crane rental across multiple units while significantly shortening cycle time. "There's an economy of scale that can be achieved."

Distribution is arguably the biggest impediment to precast's achieving widespread popularity. More so than any other alternative system discussed here, the system's proliferation is tied to the proximity of the jobsite to a manufacturing plant, typically within a 300-mile radius.

"We franchise our system to local manufacturers with exclusive distribution to control the brand against other building products," says Aaron Schoenberger, director of marketing for Superior Walls, a precast panel manufacturer that targets only foundation applications.

The company's current network of 21 franchised plants supplies builders east of a line extending from Minneapolis to Orlando, a geographic region in which basements are common. A new plant is an investment of up to $3 million, says Schoenberger.

Like SIPs, a direct relationship between a builder and the system's manufacturer is almost requisite given the planning that needs to take place before the panels are cast, a process that can take months instead of the minutes a framer might spend grabbing a few 2x4s on the way to the jobsite. -- BUILDING PRODUCTS

This article originally appeared in ProSales magazine. Maggy Baccinelli and Katy Tomasulo contributed to this report.

WinterPanel. The company offers SIPs in three panel types: StructureWall, CurtainWall, and PineClad. StructureWall panels, which replace studs and rafters, are twice as strong as a 2x4 wall, according to the manufacturer. CurtainWall panels, ideal for timber-frame or metal-frame buildings, include an interior skin of gypsum for finishing. PineClad panels offer the benefits of StructureWall but with an interior finish of tongue-and-groove pine. Foam cores are available in expanded polystyrene or polyisocyanurate. 802-254-3435. www.winterpanel.com.
	Arxx Building Products. Lightweight and pre-assembled, Arxx ICFs save builders time and money by providing formwork, framing, insulation, a vapor barrier, and strapping all in one step. The completed walls have a thermal resistance of R-22, the maker says. The product provides an STC rating of up to 50 or higher, is wind resistant up to 150 mph, and has a two- to four-hour UL/ULC fire resistance rating. An exposed X-web allows for a solid-to-solid attachment of finishing material and reduces the likelihood of screw pops, according to the company. 800-293-3210. www.arxxwalls.com.
Nudura Corp.Nudura ICFs combine six wall elements—forms, wall structure, insulation, air barrier, vapor barrier, and anchorage—into one system. The company's 8-foot-by-18-foot ICFs are the largest standard form on the market, the maker says, and the completed walls can withstand winds up to 250 mph and provide STC ratings suitable for homes, schools, and apartment buildings. The ICFs feature a hinged folding web for easy handling and efficient storage and a sturdy four-way reversible interlock that allows for interconnectivity for better utilization of cut-off segments. 866-468-6299. www.nudura.com.
	Reward Wall Systems. The T-form ICF works with the manufacturer's iForm system to make it easier to construct interior demising walls. Eleven inches in overall width, the T-form provides a 6-inch concrete core for both intersecting and longitudinal walls, the company says, and can be used for below- and above-grade applications. It is universal and reversible. 800-468-6344. www.rewardwalls.com.
R-Control Building Systems. R-Control FrameGuard Coated SIPs are treated with FrameGuard Coating—comprised of organic fungicides and a borate aprevents mold, mildew, and termite damage to its wood components, says the firm. In addition, the expanded polystyrene core is treated with Perform Guard termite protection. 800-255-0176. www.r-control.com.