State-of-the-Art and Practice Review in Concrete Sandwich Wall Panels: Materials, Design, and Construction Methods

Fray F. Pozo-Lora (), Taylor J. Sorensen (), Salam Al-Rubaye and Marc Maguire
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Fray F. Pozo-Lora: Civil & Environmental Engineering Department, Florida International University, Miami, FL 33174, USA
Taylor J. Sorensen: Civil & Construction Engineering Department, Brigham Young University, Provo, UT 84602, USA
Salam Al-Rubaye: Research and Testing, Dayton Superior Corporation, Miamisburg, OH 45342, USA
Marc Maguire: Durham School of Architectural Engineering & Construction, University of Nebraska—Lincoln, Omaha, NE 68182, USA

Sustainability, 2025, vol. 17, issue 8, 1-36

Abstract: Concrete sandwich wall panels (CSWPs) have been constructed since the early 1900s using various wythe connectors, panel geometries, and construction methods to create a structurally and thermally efficient system. Initially, thermal bridging hindered thermal efficiency due to the concrete connections and steel bars used to transfer interface forces between the concrete wythes. This issue was mitigated with the advent of polymer connectors, now widely used in the precast and tilt-up industries. As a result, CSWPs now offer buildings an efficient envelope, aiding in energy savings and reducing the need for additional construction materials and therefore contributing to the construction industry’s sustainability goals. This paper examines the current state of the practice in CSWP construction, focusing on CSWP’s construction methods, sustainability, material selection, and design processes. This manuscript delves into the history of CSWPs and showcases projects ranging from housing to industrial applications. Moreover, the materials and hardware popularly used in their construction are reviewed from the practicing engineer and researcher’s point of view and other aspects, such as environmental, architectural, and structural design, are presented. The most popular construction methods and approaches when precasting these panels on- or off-site and their associated challenges are also presented. Lastly, current deficiencies in CSWP design and construction are outlined and future directions for research and practice are suggested to advance this field further.

Keywords: concrete sandwich wall panels; fiber-reinforced plastic (FRP) shear connectors; precast concrete; tilt-up concrete; sustainability; thermal efficiency; architectural precast (search for similar items in EconPapers)
JEL-codes: O13 Q Q0 Q2 Q3 Q5 Q56 (search for similar items in EconPapers)
Date: 2025
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