DRAFT FOR REVIEW BY THE DESIGN PROFESSIONAL OF RECORD. Prepared 2026-09-10 by Advanced Formliners from an intake completed by Advanced Formliners guide specification. Not sealed. No licensed professional has reviewed this document. Bracketed text marks a decision left open.

SECTION 03 45 00
PRECAST ARCHITECTURAL CONCRETE

<Project name>, <City, State>

NOTES TO THE SPECIFIER (delete before issue)
1. This is a draft for the design professional of record to review, edit, and take responsibility for. It is not sealed and no licensed professional has reviewed it. Text in [square brackets] is a selection still to be made; text in <angle brackets> is a value to insert.
2. Structural design criteria, loads, and deflection limits are not written here. The section points at the contract drawings, or at delegated design, as chosen on the intake.
3. Standards are cited by designation. The section requires compliance with PCI manuals and specifications by name and does not reproduce their text; keep them available to the bidders.
4. PCI Architectural Certification category: Wall panels with an architectural finish, one face mixture and one texture per unit, flat or with reveals and liners: the Category AC profile, and the closest successor to the former A1 program under PCI MNL-117.

PART 1  GENERAL

1.1  SUMMARY
    A.  Section includes plant-cast architectural concrete: Cladding wall panels.
        1.  Formliner-cast textured finish on exposed concrete faces.
        2.  Connections, anchors, inserts, and accessories cast into the units and the loose hardware for erection.
        3.  Erection of the units, including bracing, welding, and grouting.
    B.  Related requirements:
        1.  Section 01 00 00, General Requirements, applies to this Section.
        2.  [Section 03 30 00 Cast-in-Place Concrete] [Section 05 12 00 Structural Steel Framing] [Section 07 92 00 Joint Sealants].

1.2  REFERENCES
    A.  The following documents form part of this Section to the extent referenced. The latest edition in force at the date of the Contract applies unless a specific edition is named.
    B.  Precast/Prestressed Concrete Institute (PCI):
        1.  PCI MNL-117, Manual for Quality Control for Plants and Production of Architectural Precast Concrete Products.
        2.  PCI MNL-135, Tolerance Manual for Precast and Prestressed Concrete Construction.
        3.  PCI MNL-120, PCI Design Handbook.
        4.  PCI MNL-122, Architectural Precast Concrete.
        5.  PCI MNL-127, Erectors Manual: Standards and Guidelines for the Erection of Precast Concrete Products.
        6.  PCI Plant Certification Program and PCI Architectural Certification categories.
        7.  PCI Field Certification (Erector) Program.
    C.  American Concrete Institute (ACI):
        1.  ACI 301, Specifications for Concrete Construction.
        2.  ACI 318, Building Code Requirements for Structural Concrete.
        3.  ACI 211.1, Standard Practice for Selecting Proportions for Normal, Heavyweight, and Mass Concrete.
    D.  ASTM International:
        1.  ASTM A615/A615M, A706/A706M, and A1064/A1064M, reinforcing bars and welded wire reinforcement.
        2.  ASTM A416/A416M, prestressing strand, where prestressed units are indicated.
        3.  ASTM A36/A36M, A276, A307, F3125/F3125M, A123/A123M, A153/A153M, structural and connection steel and its coatings.
        4.  ASTM C33/C33M, C150/C150M, C595/C595M, C618, C989/C989M, C1240, C1602/C1602M, concrete materials.
        5.  ASTM C260/C260M, C494/C494M, C1017/C1017M, C979/C979M, admixtures and pigments.
        6.  ASTM C1107/C1107M, nonshrink grout. ASTM C881/C881M, epoxy adhesives. ASTM C920, elastomeric sealants.
        7.  ASTM C31/C31M, C39/C39M, C143/C143M, C231/C231M, C138/C138M, C1064/C1064M, field and laboratory testing of concrete.
    E.  American Welding Society (AWS): AWS D1.1/D1.1M, D1.4/D1.4M, and D1.6/D1.6M.

1.3  DEFINITIONS
    A.  Architect: the design professional named in the Conditions of the Contract, whose review and acceptance are required where this Section says so.
    B.  Design reference sample: a small sample, produced by the producer from the specified materials, that establishes the intended color, texture, and finish before production begins.
    C.  Mockup: a full-size unit or assembly produced with production methods, used to confirm appearance, tolerances, and construction before production units are cast.
    D.  Formliner, textured: a liner attached to the form face that casts a pattern, relief, or texture into the concrete.
    E.  Exposed face: any surface of a unit visible in the completed work, including returns, reveals, and soffits.

1.4  PREINSTALLATION MEETING
    A.  Convene a meeting at the producer's plant or the Project site before production and again before erection, attended by the Contractor, the producer, the erector, the Architect, and the trades whose work connects to the units.
    B.  Review the approved samples and mockup, the finish acceptance criteria and viewing distance, the sequence of casting and erection, the connection and bracing plan, joint and sealant coordination, protection of finished faces, and the repair procedure and who approves repairs.
    C.  Review formliner sheet layout, seam placement relative to reveals and panel joints, pattern orientation, and the number of uses the liner is rated for.

1.5  ACTION SUBMITTALS
    A.  Product data: for each material, admixture, pigment, reinforcement, connection component, insulation, formliner, thin brick, form-release agent, sealer, and repair material.
    B.  Shop drawings: unit elevations, sections, and dimensions; reinforcement and prestressing; connections, inserts, and lifting devices; joint locations and widths; finish designation for each face; reveal and formliner layout; handling and erection sequence; and the relationship of each unit to adjacent construction. Show every exposed face and identify which are finished and which are returns.
    C.  Design reference samples:
        1.  Sets of three, approximately 12 by 12 by 2 in., for each color, texture, and finish, before production begins. Samples show the range of color and texture to be expected.
        2.  Where samples are rejected, resubmit until the Architect accepts one set. The accepted set is the design reference sample and is kept at the plant and on site.
    D.  Formliner samples: a manufacturer sample of the specified pattern, and a cast sample from the design reference sample set showing the pattern at true relief.
    E.  Mixture designs: proportions and material sources for each face and backup mixture, with the trial batch results that support them.

1.6  INFORMATIONAL SUBMITTALS
    A.  Producer qualification: current PCI Plant Certification in Architectural Category [AC] for the plant that will cast the units. Include the certificate.
    B.  Erector qualification: current PCI Field Certification for the erector, at the category the Plant Certification requires, or evidence of an equivalent qualification acceptable to the Architect.
    C.  Welder qualifications per AWS D1.1/D1.1M and D1.4/D1.4M, current within the period the program requires.
    D.  Material certificates: for cement, aggregates, admixtures, pigments, reinforcement, prestressing strand, connection steel and coatings, insulation, grout, and sealer.
    E.  Test reports: concrete trial batches; aggregate soundness and reactivity; and the plant quality control records for production units when requested.
    F.  Formliner manufacturer data: pattern, relief depth, draft, sheet size, material, rated number of uses, and recommended form-release agent.
    G.  Erection and bracing plan, and the lifting and handling procedure for each unit type.
    H.  Repair procedure and materials, submitted before the first repair is made.

1.7  QUALITY ASSURANCE
    A.  Producer: a plant certified under the PCI Plant Certification Program in Architectural Category [AC] at the time of bidding and throughout production. Loss of certification during the Work is cause for rejection of units cast after the loss.
    B.  Erector: certified under the PCI Field Certification Program.
    C.  Quality control: in accordance with PCI MNL-117, administered by the producer and open to inspection by the Owner and the Architect at any time during working hours.
    D.  Welding: qualified procedures and welders per AWS D1.1/D1.1M for structural steel and AWS D1.4/D1.4M for reinforcing steel.
    E.  Mockup:
        1.  Cast a full-size mockup unit of each finish, showing the formliner pattern and a liner seam, using production methods and materials, before production begins.
        2.  The accepted mockup establishes the range of color, texture, and workmanship. [Retain it until Substantial Completion.] [Incorporate it into the Work where shown.]
    F.  Finish acceptance:
        1.  Production units are judged against the accepted mockup, viewed in daylight, without magnification, at a distance of 20 feet.
        2.  Color and texture within the range of the accepted standard, with no unit that reads as a different mixture at the stated distance. Cracks, chips, spalls, honeycomb, form-line offsets, and staining are unacceptable on exposed faces except as the repair procedure allows.

1.8  DELIVERY, STORAGE, AND HANDLING
    A.  Handle and ship units in the orientation and with the supports shown on the shop drawings. Lift only with the devices cast in for that purpose.
    B.  Store units off the ground on dunnage at the points of support, separated so that no exposed face touches another unit, chain, or dunnage, and protected from staining, rust, and run-off.
    C.  Store formliners flat, out of sunlight, and clean; damaged or distorted liners are not used on exposed faces.

1.9  SEQUENCING AND SCHEDULING
    A.  Do not begin production units until the design reference samples and the mockup have been accepted in writing.
    B.  Coordinate delivery and erection with the structure so that no unit is stored on site longer than necessary.

PART 2  PRODUCTS

2.1  PERFORMANCE REQUIREMENTS
    A.  Structural performance: as indicated on the Contract Drawings. Design lifting devices and connections for handling, shipping, and erection stresses in addition to the loads indicated.
    B.  Thermal and moisture movement: provide for movement at joints and connections so that restraint does not crack the units or damage adjacent construction.
    C.  Durability: [air entrain concrete in exposed faces for freeze-thaw exposure] [freeze-thaw exposure does not apply at the Project location].

2.2  REINFORCEMENT AND PRESTRESSING
    A.  Reinforcing bars: ASTM A615/A615M Grade 60, or ASTM A706/A706M where welded. Welded wire reinforcement: ASTM A1064/A1064M.
    B.  Where cover to an exposed face is less than 1-1/2 in., or where the face is acid etched or sandblasted, use [galvanized reinforcement per ASTM A767/A767M] [epoxy-coated reinforcement per ASTM A775/A775M] [stainless steel reinforcement] to prevent rust staining. Non-corroding spacers and chairs only.
    C.  Prestressing strand, where indicated: ASTM A416/A416M, Grade 270, low relaxation.
    D.  Supports: plastic or stainless steel where they will be within 1 in. of an exposed face; no bare steel touching an exposed face.

2.3  CONNECTION MATERIALS
    A.  Structural shapes, plates, and bars: ASTM A36/A36M. Bolts: ASTM A307 or ASTM F3125/F3125M as indicated. Anchor and headed studs: ASTM A108, welded per AWS D1.1/D1.1M.
    B.  Finish: hot-dip galvanized per ASTM A123/A123M or A153/A153M where exposed to weather or embedded within 1-1/2 in. of an exposed face; zinc-rich touch-up of field welds and damaged coating. Where connections are exposed in the finished work, stainless steel per ASTM A276, Type 304 or 316 as indicated.
    C.  Inserts and lifting devices: as selected by the producer for the loads and the unit geometry, of a type that leaves no ferrous metal within 1 in. of an exposed face after erection.
    D.  Bearing pads: elastomeric, of the durometer and thickness on the shop drawings; nonshrink grout per ASTM C1107/C1107M where bearing is grouted.

2.4  CONCRETE MATERIALS
    A.  Portland cement: ASTM C150/C150M, [white] [gray] cement for face mixtures, of one type and one source for the duration of the Work. Blended cement per ASTM C595/C595M where the producer proposes it, subject to acceptance of the design reference sample made with it.
    B.  Supplementary cementitious materials: fly ash per ASTM C618, slag cement per ASTM C989/C989M, silica fume per ASTM C1240. Use in face mixtures only where the accepted design reference sample was made with the same materials and proportions.
    C.  Aggregates: ASTM C33/C33M, from one source for the duration of the Work. Face aggregates are selected to match the accepted design reference sample and are free of iron pyrites and other staining minerals.
    D.  Water: ASTM C1602/C1602M.
    E.  Admixtures: air entraining per ASTM C260/C260M; water reducing, retarding, and accelerating per ASTM C494/C494M; high-range water reducing per ASTM C1017/C1017M. No admixture containing calcium chloride.
    F.  Pigments: ASTM C979/C979M, inorganic, from one manufacturer for the duration of the Work.

2.5  TEXTURED FORMLINERS
    A.  Formliner: pattern "<pattern name and code>", basis of design Advanced Formliners, Sparta, Wisconsin, Solocast Seamless line. Liners of another manufacturer producing the same pattern, relief, and draft may be proposed under Division 01 and are accepted only on a cast sample matched to the design reference sample.
    B.  Material: elastomeric (polyurethane) for multiple uses, or a single-use plastic liner, as the producer proposes for the number of casts required. Draft on every relief face not less than the manufacturer publishes for the pattern, and in no case less than 1:8 unless the pattern is specifically designed for stripping at a lesser draft.
    C.  Layout: lay out liner sheets on the shop drawings with seams at reveals, rustications, or panel joints where the pattern allows. Where a seam must fall within a field, butt sheets tightly, match pattern registration, and seal the seam so that no fin or offset shows on the cast face at the acceptance distance.
    D.  Uses: retire a multi-use liner before the pattern softens, fills, or tears; the cast face of the last unit must match the accepted mockup. Do not reuse a single-use liner.
    E.  Form-release agent: compatible with the liner material and the finish, applied thinly and evenly, and not one that stains or interferes with a sealer or coating specified elsewhere.

2.6  CONCRETE MIXTURES
    A.  Proportion mixtures per ACI 211.1 and trial batches. Face mixture and backup mixture may differ; the face mixture is not less than 1 in. thick after consolidation, and thicker where the finish removes surface material.
    B.  Compressive strength: not less than 5,000 psi at 28 days, and not less than the release strength on the shop drawings before stripping or detensioning.
    C.  Air content of exposed-face concrete: [4 to 6 percent for freeze-thaw exposure], measured per ASTM C231/C231M.
    D.  Water-cementitious materials ratio: not more than 0.45 for exposed-face concrete, and not more than 0.40 where the face is exposed to de-icing salts.
    E.  Consistency: as the producer establishes for full consolidation without segregation; self-consolidating concrete may be used where the design reference sample was made with it.
    F.  One source for cement, aggregate, and pigment for the duration of the Work; a change of source requires a new design reference sample and acceptance.

2.7  FORMS AND MOLDS
    A.  Forms: rigid, dimensionally stable, and tight, producing units within the tolerances of Article 2.9, with the corners, reveals, drips, and edges shown on the drawings. Form face material for exposed faces free of defects that would transfer to the concrete.
    B.  Chamfers, reveals, and rustications: as detailed, with draft on every face that is stripped past; no sharp arrises on exposed edges unless detailed and accepted on the mockup.
    C.  Liner attachment: fixed to the form so that the liner does not lift, shift, or wrinkle under placement; liner joints and edges sealed against paste leakage.
    D.  Form-release agent: one that leaves no residue affecting color, bond of finishes or sealers, or the appearance of the exposed face.

2.8  FABRICATION
    A.  Fabricate units in the certified plant per PCI MNL-117, with the reinforcement, connections, and inserts positioned within tolerance and secured so that they do not move during placement.
    B.  Place the face mixture against the form face first where a separate backup mixture is used, and place the backup before the face mixture reaches initial set so that the two bond.
    C.  Cure units so that color is uniform across each unit and from unit to unit; do not let part of a unit dry faster than the rest. Steam curing, where used, is uniform across the unit.
    D.  Strip forms and liners at a strength that does not damage arrises, relief, or brick edges. Do not pry against an exposed face.
    E.  Identify each unit with its shop drawing mark on a face that is concealed in the completed work.

2.9  FABRICATION TOLERANCES
    A.  Fabricate units within the product tolerances of PCI MNL-135 for Architectural Category [AC], unless a tighter tolerance is shown on the drawings.
    B.  Liner seams and pattern registration: no offset at a seam greater than 1/16 in. on the cast face, and pattern alignment across a panel joint within 1/8 in. where the pattern is continuous.
    C.  Surface flatness of smooth exposed faces: within 1/8 in. in 10 ft; form-line offsets within 1/16 in. on exposed faces.

2.10  FINISHES
    A.  Finish each exposed face as scheduled on the drawings and matched to the accepted mockup and design reference sample. Finish returns and soffits to match the adjacent face unless another finish is scheduled.
    B.  Formliner texture: full relief, crisp arrises, no bug holes larger than the mockup shows, no fins or paste bleed at seams, and pattern orientation as shown.
    C.  Repairs: only by the accepted repair procedure and materials, matched in color and texture, and invisible at the acceptance viewing distance. Units with repairs that fail this test are rejected.

2.11  SOURCE QUALITY CONTROL
    A.  Plant quality control per PCI MNL-117, including inspection of forms, reinforcement, inserts, and finishes before and after casting, with records available to the Architect.
    B.  Concrete testing: sample and test each mixture per ASTM C31/C31M, C39/C39M, C143/C143M, C231/C231M, and C1064/C1064M at the frequency of ACI 301, and at not less than one set per day of casting for exposed-face concrete.
    C.  Cleaning after stripping: remove form-release residue, paste film, and curing compound from exposed faces by the method accepted on the mockup; no acid on brick faces or metal, and no method that alters color or texture.
    D.  Architect inspection: the Architect may inspect units at the plant at any stage. Acceptance of a unit at the plant does not waive rejection of a unit damaged afterwards.

PART 3  EXECUTION

3.1  EXAMINATION
    A.  Examine supporting structure, bearing surfaces, anchors, and embedded items for location, elevation, and condition before erection. Report variances that would put units outside the erection tolerances, and do not proceed until they are corrected.
    B.  Verify that field dimensions match the shop drawings, and that adjacent work is coordinated with the joints and reveals of the units.

3.2  ERECTION
    A.  Erect units per PCI MNL-127 and the accepted erection and bracing plan, by the certified erector, with lifting devices, rigging, and crane positions that do not overstress the units. Set each unit level, plumb, and to line on shims and bearing pads, and brace it until the permanent connections are complete.
    B.  Connections: weld, bolt, or grout per the shop drawings. Protect exposed faces from weld spatter and heat; clean and coat field welds and damaged galvanizing with zinc-rich coating. Grout bearing and connection pockets solid and cure the grout.
    C.  Do not field cut, core, or drill units except where the shop drawings show it or the producer approves it in writing.
    D.  Joints: maintain the joint width shown, [3/4 in. typical] uniform along the full length, with backer rod and sealant by others under Section 07 92 00.

3.3  ERECTION TOLERANCES
    A.  Erect units within the erection tolerances of PCI MNL-135 for Architectural Category [AC], and within the tighter of those tolerances and the joint width shown.
    B.  Jog between adjacent exposed faces at a joint not more than 1/4 in. for smooth faces, and not more than 1/8 in. where thin brick or a formliner pattern continues across the joint.
    C.  Where the structure is out of tolerance, do not force units to line; report and resolve before setting.

3.4  FIELD QUALITY CONTROL
    A.  The Owner may engage a testing agency to inspect erection, connections, welds, and grout. Field welds are visually inspected and, where the drawings require, tested per AWS D1.1/D1.1M.
    B.  Finish inspection after erection: the Architect reviews exposed faces at the acceptance viewing distance in daylight and identifies units for repair or replacement.

3.5  REPAIRS
    A.  Repair damage only by the accepted procedure, using materials matched to the unit and the finish, by workers who repaired the mockup or the first accepted repair. Repairs must be invisible at the acceptance distance; otherwise the unit is replaced at no change in the Contract Sum or Time.
    B.  Cracks on exposed faces: reviewed by the Architect. Structural cracks are cause for rejection. Non-structural cracks may be repaired by epoxy injection per ASTM C881/C881M and finished to match only where the Architect accepts the repair.

3.6  CLEANING AND PROTECTION
    A.  Clean exposed faces after erection by the method accepted on the mockup, starting with water and mild detergent and escalating only with the Architect's acceptance. No acid on thin brick faces, connections, or adjacent metal. Protect adjacent materials from run-off.
    B.  Protect finished faces from staining, sealant smears, weld spatter, and construction traffic until Substantial Completion. Remove protection and leave surfaces clean.
    C.  Water repellent: [apply a penetrating silane or siloxane sealer under Section 07 19 00 after cleaning, accepted first on a sample area for appearance] [not required].

END OF SECTION 03 45 00