Dennis Drake, owner of Drake Excavating of Champaign, IL, became a certified installer for precast concrete foundations last year. He selected Superior Walls by Precast Concrete Solutions of Springfield, IL, because the company manufactures a Green Approved Product certified by the National Association of Home Builders Research Center. It also qualifies for the Energy Star rating from the Environmental Protection Agency.
Superior Walls provides an R12.5 insulation factor and requires no additional damp-proofing. “With the extra insulation, precast foundation walls lower energy use by as much as 30% and reduce mold and other moisture issues,” says Drake.
Drake explains that precast is energy friendly because it reduces energy leakage. This results in lower energy costs for the homeowner.
Because the precast panels include concrete studs overlaid with metal, they reduce the need for wood, which helps the environment. The precast product uses 5,000-psi concrete, according Drake. To reduce mold buildup, the manufacturer engineered the precast concrete panels with a lower water-to-cement ratio. This also ensures durability and helps prevent the transfer of moisture through the walls.
“The factory punches the holes for plumbing and electrical. And it’s easy to add extra insulation,” Drake adds.
Because the precast foundation walls arrive onsite ready to install, they eliminate the soil contamination and job-site waste normally associated with poured concrete foundation walls.
Excavating for a Precast Foundation
In addition to its own customers, Drake Excavating is a subcontractor to Drake Homes, which is owned by Drake’s father, Steve. Drake Homes focuses on the construction of high-end luxury homes and light commercial construction such as banks, gas stations, convenience stores, churches, and libraries. They also build subdivisions of up to 120 homes. They have 50 full-time employees.
A recent project for the father-son team involved a new home with a full 2,000-square-foot basement and an additional 1,200 square feet of porch and basement area. The home is located near Champaign, Ill. Dennis explains that the home was built on the high point of a former soybean field near a flood plain. “Precast concrete provided an excellent moisture barrier,” he says.
Foundation in Five Days
Using precast concrete foundation walls made it possible for Drake Excavating to complete the foundation in five days. “This saves a couple of days compared to a conventional concrete installation,” said Dennis.
“We complete the home sooner, and the new owner moves in earlier, which makes everyone happy,” adds Steve.
On day one, Drake Excavating identified the location of the basement on the property with a robotic total station. “This instrument tells you where every corner is so it takes the tape measure out of placing the foundation,” says Dennis.
Drake Excavating installed and compacted the gravel on day two and placed the precast foundation walls on day three. On day four, the company installed the plumbing and prepared the floor for pouring concrete. On day five, it completed the foundation by pouring the concrete floor.
Dennis used a Case CX210B excavator equipped with a 2-cubic-yard bucket to remove 662 cubic yards of dirt to form the basement work area. He dug a minimum 2-foot over-dig at the base of the foundation and placed a wide bench footing. Four-inch perforated pipe buried in gravel provided drainage for the floor.
“I flipped the bucket around backward to sling the stone into the hole,” Dennis explained. He said using the bucket in the “facing” position speeds up the gravel installation by giving him about 6 feet of extra reach. It also saves having to bring another machine on site.
After preparing the footing, Drake Excavating used a crane to install the precast concrete foundation panels. “They hook together in a way that’s similar to tongue-and-groove flooring,” said Dennis. He sealed the joints with a Superior Walls prescribed sealant.
For the interior finish, Drake Homes installed the plumbing and electrical. The company attached the drywall with screws. No additional damp proofing was necessary.
Excavating the Rest of the Site
Dennis used his Case 850K crawler dozer to build a 500-foot driveway off the main road. For the foundation base, the septic tank and the water line, he chose his Case 580 Super M Series 3 loader/backhoe. While he operates all Case equipment, he especially enjoys the loader/backhoe. In 2008, he was the runner-up in the Case Rodeo Series event held during the CONEXPO trade show.
To move rock around the site and fill in the garage gravel base, Dennis drove his Case 440 compact track loader. “We like to use as much Case iron as we can on a job,” says Dennis. “Case equipment gives trouble-free performance.”
Consistent with the Drake family’s commitment to green building practices, Dennis used a 10% biodiesel fuel mixture in his equipment. “Our CX210B uses one-third less fuel than the excavator we purchased in 2004,” says Dennis.