Prefabricated Modular Ceramic Precast Panels

The engineered design allows for significant gravity loads, high wind loads, seismic movements, and high moisture exposure without deterioration.


Benefits of building with ACI Precast composite ceramic panels:

  • ASTM E119-12:Three Hour Rate Load Bearing Fire Assembly

  • Light weight building envelopes & enclosures (17-23lbs)

  • High strength to weight ratio structural composite action

  • Rapid bolted steel to steel installation connections

  • Continuous Insulated (CI) thermal break at steel line

  • Vapor barrier: impervious to moisture mold free

  • Corrosion resistance PH 3-11

  • High security, hardened surfaces. 8,000 psi +

  • High impact resistant Level 3 Min UL752

  • Flexural strength for resistant to seismic movements and high wind loads

  • Manufactured in controlled environment

  • Accelerated modular construction schedules

  • Fur out – ready to receive interior finishes

  • Architectural finishes and shapes of choice


ASTM E119-12 3 Hour Fire Rated Load Bearing Structural Assembly

Fenestration Test Laboratory, Inc. Test Results:

Test Sample: (2) 5’x10’ wall assembly constructed in a 10’x10’ 6”x 1-1/4 header and sill 6” vertical stud 16” O.C with ceramic pre-cast exterior of panel and 5/8 Fire Shield Extended Exposure Gypsum sheathing on interior of panel. Hilti fire stop caulk applied between panels.  

The test proceeds by subjecting the exposed side of the panel to rapidly increasing temperature, exceeding 1,000°F after 6 minutes, exceeding 1,500°F after 30 minutes, and approaching 2,000°F after 3 hours.  Importantly, as these were load bearing panels, a vertical live load of 2,600 lbs. per linear foot of wall (26,000 lbs. total) was continuously maintained on the top surface of the wall during the fire test.  Temperatures on the unexposed wall surface are measured, and are not allowed to exceed 325°F per the ASTM Standard.  For the tested panels, unexposed surface temperatures only reached 100°F at 3 hours, far below the 325°F allowed by the standard.  No visible changes in the panel had occurred when the test was terminated after 3 hour of exposure, and no passage of flame or hot gas was observed.  The test panels in the furnace are shown near the end of the 3 hour exposure period.




The Benefits of Panel Prefabrication

Pre-fabrication significantly reduce project schedule, administration, trade overlap problems, bringing down projects costs associated with the simultaneous management of multiple materials and trades.

The design and production process for the panels is outlined in this section.  Design of the panelized structure and of the panel assemblies themselves is completed with custom-tailored BIM software that provides modeling, engineering, and estimating tools.  The software generates shop drawings for the individual panel components, as well as precise budgetary values for materials, labor, profit, and overhead on a particular job.  Panels can be designed for load bearing and non-load bearing applications. Shop drawings are generated for panels and connections, designed per engineered & architectural specifications. 

The shop drawings are drawn from Revit and BIM formats, allowing designers to 3D model all members and materials implemented in the fabrication process. The detailed modeling software provides a high level of confidence, as well as a transparent design process with architects, engineers, general contractors, erectors, and fabricators.  Panel shop drawings for construction sealed by a Professional Engineer and approved by the Project Architect prior to the start of panel fabrication.


ACI Precast proprietary composite panel design incorporates continuous insulation design. This allows for significant reduction in thermal bridging at the stud line solving the most common area of thermal transfer and energy loss in conventional buildings.The insulation incorporated into the system consists of EPS foam, used to totally encapsulate the steel framing to promote net zero design. This encapsulation creates a continuous thermal break between the inside and outside surfaces of the wall system that greatly reduces the flow of heat through the wall cavity.

US Patent # 7, 681, 368 B1