After 40 years of growth in the precast arena, polymer concrete has at last come of age. It is no longer specified as a "substitute" for cementations precast, but because of its outstanding innate properties it is now used in all types of building structures.
  
      The following presentation depicts what one company, Metro Cast has completed during the past 3 years. It is helping to broaden the ever expanding field of "Art in Architecture" through the use of polymer concrete.
Projects :
African Heritage Cultural Center
  Detroit, Michigan
  Arhitect: Arhitects International Inc.
  Contractor: Usztan Construction Inc.
 
   Originally specified in cementations concrete, this complex shape, the positioning of the columns for the erection and the massive weight precluded it's use.
The cost would be prohibiting.
   The design was necessary to create the theme of the entire structure. Polymer concrete not only created the aesthetic image but did it at an overall savings of 30%.
 

   Required: thirty nine (39) columns, each designed in three pieces.
   The base: 3'-0' in diameter, has a top recess and curved perimeter.
   Middle section: tapered with top recess.
   Top capital: a complicated taper with bottom return and top recess.
   Manufacturing procedure: three (3) forms (one for each section) permitted the casting of one column daily.

 
 
Lambert International Airport
  St. Louis, Missouri
  Arhitect: Trivers Associates
  Contractor: Interface Contruction Corporation
 
    Novel rail tubes that guide arriving passengers into a new terminal presented the architects with an interesting problem. Aluminum which was the original material of choice could only be made in small sections and since the serpentine nature of the rail shape precluded any extended further use of molds, the cost became prohibitive. Also, the bright red color specified excluded other materials.

   Only with polymer concrete could this project reach fruition. Each tube was 24" in diameter, 1" tk. and varied from 4'- 0" in length to 5'- 0" in lenght. Two (2) different tube varied with each length from 9'-7" to 29'-0" some with closed ends.
    Two (2) forms for each diameter were cast using polymer concrete material. The tube was cast in two (2) sections with parallel weld plates cast in. These two (2) pieces were joined at the factory. The joints were concealed by filling them with basic matrix.

 
Edgewood College Science Building
  Madison, Wisconsin
  Arhitect: Durant Group, Inc.
  Contractor: J.F. Findorff & Sons Inc.
 
   Originally designed as a fast track project using cementations precast.

   When the total weight for it was calculated, each 10'-0" X 15'-0" section would weight over 12,000lbs, determining that the structural steel would be over burdened.
   But with polymer concrete panels cast over simple steel stud frames such sections would weight only 2,000lbs. Further erection time and of type of equipment involved would be much less expensive.
 

   
   The curved area was cast over plywood forms forming a hallow bull nose. Rigid foam was used to prevent the matrix from filling this area, thus saving additional weight. Note, the monolithic corners.
 
St. Nicholas Orthodox Church
  Troy, Michigan
  Design: Concept by owner
 

   Metro Cast's engineers were commissioned to design three (3) crosses which could withstand the elements; retain their color and yet be reasonable in cost.

   At the bottom of each cross two round forms with an octagon base provide for the attachment to the top of the tower.

   The finished surface was created by using a copper powder pigment to match the copper shingles on the tower.
 
Zurn Water Pump Station
  Louisville, Kentucky
  Arhitect: Louis & Henry Group
  Contractor: Parco Construction
 
   In order to restore the massive fluted columns of this structure, the main architectural feature of this building (now a museum) was to cast them with polymer concrete. Erection of cementations precast would have been extremely difficult and there was not enough volume to amortize the cost of the form work.
 

   The column is 34'-0' high with a 3" tk. ribbed (fluted) texture. Its diameter tapers up from a 4'-2" base to a 3'-10" crown and includes an 8" bull nose top.

   The full 34'-0" mold was made in Metro Cast's carpentry shop (including the bull nose), and then cut into three (3) equal sections.

   Once installed, the 3 pieces created the appearance of one solid monolithic column.

 
Metro Detroit International Airport
  Romulus, Michigan
  Arhitect: Varner & Associates Inc.
  Contractor: Walbridge Aldinger Construction
 

   Continuity of design required that the new exterior canopy matches existing. These were 9"tk. individually (no two alike) sculptured sections.

   The original precaster was no longer in business and the original form did not exist. Fortunately, a local polymer concrete manufacturer, Metro Cast came up with a solution.

   An almost perfect color match plus rigid foam blocks encapsulated in 3" tk. panels reinforced with fiberglass proved to be the answer.
 
Christ The Savior Lutheran Church
  Farmington, Michigan
  Sculptor: Joseph DeLauro, PHD
 

   Professor Joseph DeLauro, formerly dean of fine arts at the University of Windsor, Canada, was commissioned by the church to create a relief of Christ in an open area above the main entrance.

   With knowledge gleaned at a polymer concrete facility and working with skilled craftsmen, he created not just a relief but a full body of Christ apparently passing through the wall to greet the incoming laity.

 

   The entire skin was only 3/4" tk., reinforced with fiberglass and stabilized with metal re-rods. The true metallic color was obtained from powdered bronze pigment blended into the matrix. It was cast face down.

   This 13'-0" magnificent rendition could only have been created with polymer concrete since the existing structure could not support the weight of conventional casting material.