PCWS example

PCWS Design

From over 4 decades of experience

I began with the end in mind; simple design and high performance building walls that excel both structurally and from a Building Science perspective. My journey began by meticulously examining each step and component required to construct such walls. My goal was to find ways to simplify installation, reduce costs, and ensure easy verification of assembly in a single visit for optimal performance.

Through extensive research and analysis, I discovered that concrete sandwich walls hold great promise in terms of simplicity and high performance. However, I also identified the major challenges posed by expensive and time-consuming proprietary formwork systems. I realized the need to break free from the industry’s dependence on inflexible forming systems and simplify the construction of high-performance concrete walls.

Rethinking tradition

How it Started

The idea for the Perfect Concrete Wall System came to me while designing an addition with a full basement and tornado room, all constructed with concrete. I wanted to ensure that these concrete rooms would be comfortable and not feel like typical basements. After researching, I came across an article by Joseph Lstiburek of the Building Science Corporation, dated October 26, 2006, which convinced me that the key to achieving a comfortable living space with exterior concrete walls is through composite acting insulated sandwich walls.

Discovering sandwich walls

With my extensive experience managing construction projects for over 45 years, including both cast-in-place and precast concrete, I had previously used sandwich walls only with precast. However, when I priced my addition, I discovered that the walls using this system were more than three times the cost of normal cast-in-place walls. This prompted me to delve deeper into the reasons behind the high cost and the challenges in achieving precast-like quality.

Reducing costs

I aimed to find a solution that would provide high quality comparable to precast walls but at the cost of normal cast-in-place walls. My goal was to eliminate the need for a crane on the job site, reduce heavy trucking costs, eliminate modular forms, wall ties, and thermal leaks, minimize joints in the rigid insulation, enable visual inspection of insulation and reinforcement before any form work, reduce the time required to form and place the wall concrete, and allow for the reuse of shuttering plywood in other areas of the building.

With these objectives in mind, I developed the Perfect Concrete Wall System to address these challenges and deliver a cost-effective solution with superior quality.

Patent cover

I am an Engineer. I serve mankind by making dreams come true.

Founder, Joseph Racciua

The Perfect Concrete Wall Solution foundation wall sketch
Professional Engineer, Building Scientist

About Joseph

With 45 years of experience in the construction industry, spanning public works, healthcare, commercial, retail, industrial, and residential projects, I bring unique expertise in value analysis, constructibility, scheduling, and sustainable concepts. As a licensed Professional Engineer and LEED® Accredited Professional, I am passionate about delivering elegantly simple, verifiable, and cost-effective building envelope solutions.

Throughout history, building enclosures have often been porous to air and water. However, the energy crisis of the 1970s prompted a focus on energy conservation, leading to increased insulation and sealed gaps. By the 1990s, the prevalence of “sick building syndrome” necessitated more complex enclosures with specialized materials. Today, these enclosures are costly, potentially toxic, and challenging to construct using standard practices.

To address these challenges, I have developed a solution using only three materials that meet all building envelope requirements while aligning with current construction standards. This approach simplifies construction, ensures compliance with evolving codes, reduces costs, and enhances quality control in the field. Leveraging my expertise and innovative thinking, I have found a practical and efficient way to meet the demands of the future building industry.