The Heldrich


10 Livingston Avenue, New Brunswick, NJ


Heldrich Assoc. LLC., New Brunswick, NJ


James R. McAuliffe Architects, Atlanta, GA


DeSimone Consulting Engineers, New York, NY


Keating Building Corporation, Philadelphia, PA

Project Scope

Sq. Footage:

40,150 sf (wall panels)




The Heldrich
The Heldrich
The Heldrich
The Heldrich
The Heldrich
The Heldrich

CarbonCast® Delivers High Style, Low Weight and More Sustainable Design

CarbonCast architectural precast panels make a classic facade possible in mixed use project including hotels and condominium space. Innovative, lightweight panels were fabricated to a thickness of 10” to allow the deep reveals and articulation the architect was looking for – for very nearly the same cost as thinner, and less dramatic, 6” conventional precast panels.

The thin-faced, back-ribbed concrete panels constructed using insulating EPS foam stay-in-place forms, weighed only 32 pounds per square foot – about 70% less than conventional 10” precast concrete panels. The lighter panels minimized crane requirements, preserved piece size, and kept erection costs under control. The cost of the EPS foam in the panels was lower than that of the concrete, so each additional inch of thickness cost half that of conventional precast.

The extraordinary panel depth enabled deep reveals and window recesses that would have been heavy and cost-prohibitive in conventional precast. In addition, CarbonCast technology was used to lighten heavy cornices. Over $90,000 worth of perimeter steel and labor costs were saved as a result of the lighter panels.

To complement the granite on the building face, the panels are finished with eco-friendly shot blasting, which uses recyclable steel shot instead of sand media, for a highly consistent color and texture that gives the appearance of limestone. The end result is a high-end, 10 story building that features a 250-room hotel and conference center, retail space, academic space, and luxury condominiums.

The CarbonCast Architectural Cladding Panels use carbon fiber grid as secondary reinforcement in the panel face, replacing conventional steel mesh.

Because carbon fiber will not corrode and controls cracks better than steel mesh, conventional CarbonCast panels use significantly less concrete in the panel face because there is not steel mesh to protect from the corrosive effects of wind-driven rain and ice.

The dramatic reduction in concrete results in panel weights that are significantly less than conventional precast, about equal to brick veneers, and enable more richly detailed facades than steel-stud backed precast systems.

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