CONFIGURATION-1
Configuration 1 represents VREcast’s flagship connector assembly—a precision-engineered solution that delivers uncompromising structural integrity while maintaining complete thermal isolation. Designed for projects demanding maximum load transfer efficiency and verified performance, this system combines mechanical reliability with sustainable design principles.
How It Works?
Component 2
Dual CFS Channel Sections
Cold-formed steel channels manufactured from 95% recycled steel. Factory-precision forming with integrated MEP pathways.
Component 1
GFRP Zig-Zag Bars
V-shaped Glass Fiber Reinforced Polymer bars positioned to transfer loads while maintaining thermal isolation. 90% lower thermal conductivity than steel.
Component 3
VRE-Connector Hardware
Mechanical fastening system securing GFRP bars between channels. Symmetrical load transfer with tool-free alignment.
Integrated Structural System
These three components work together to transfer design loads from steel framing to concrete panels without creating thermal pathways—eliminating thermal bridging that undermines energy performance in conventional systems.
Why Choose Configuration-1?
GFRP zig-zag bars positioned between dual CFS channels and fastened with VRE-connectors form the structural connection assembly for metal joists and studs, transferring loads without thermal bridging and maintaining complete thermal isolation between the concrete wythe and steel framing.
Complete Thermal Isolation
100% thermal break achievement with ¼" separation gap—zero thermal bridging through structural connections.
Superior Load Transfer
V-shaped GFRP geometry resists in-plane shear forces and transfers multi-story gravity loads with verified capacity.
Triple-Component Integration
GFRP zig-zag bars sandwiched between dual CFS channels and secured with VRE-connector hardware.
Laboratory-Validated Performance
Proven structural capacity under ASTM E72 protocols with controlled, ductile response under extreme loading.
Sustainable Design
95% recycled steel content, 40% concrete volume reduction, and 40% reduction in life-cycle climate impact.
Factory-Controlled Precision
VRE-connectors installed during panel fabrication with quality verification before panels leave factory.
Ideal Applications
- Multi-story residential and commercial buildings requiring consistent thermal performance
- Institutional facilities (hospitals, schools) with stringent energy codes
- High-rise construction demanding reliable load transfer
- Fast-track projects benefiting from factory-verified systems
- Sustainable developments targeting LEED and low embodied carbon
Specifications
GFRP Zig-Zag Bars
½" Nominal Diameter
CONFIGURATION
V-shaped intersecting shear planes.
Material
Glass Fiber Reinforced Polymer (ASTM D7957).
Thermal Conductivity
0.25–0.35 W/m·K (vs. 45–60 for steel).
Anhoring
Embedded anchoring developing full shear capacity.
Dual CFS Channel Sections
Cold-Formed Steel
Material
95% recycled steel content.
Manufacturing
Standardized profiles with factory-precision forming.
Integration
Integrated pathways for MEP services within panel cavity.
VRE-Connector Hardware
Mechanical Fastening System
Function
Mechanical fastening system securing GFRP bars.
Load Transfer
Symmetrical load transfer preventing eccentric forces.
Assembly
Tool-free alignment during panel assembly.
Thermal Advantage
½" separation gap—100% thermal isolation.
R-24 minimum (R-40+ achievable).
30% improvement vs traditional precast.
Zero thermal bridging.
Structural Performance
V-shaped GFRP geometry for in-plane forces.
Multi-story load capacity.
Laboratory-validated under ASTM E72.
Controlled, ductile response.
Energy Performance
Superior thermal efficiency reducing operational energy.
Enhanced building envelope targeting LEED® v4.
Durable, recyclable materials at end of service life.
Manufacturing & Installation
Factory-controlled precision meets installation efficiency
Factory Installation
VRE-connectors and GFRP bars installed during panel fabrication with quality verification.
Pre-Assembly
Tool-free mechanical connectors eliminate field coordination and on-site assembly.
Rapid Deployment
Panels arrive crane-ready for immediate placement, reducing labor and schedule.
Sustainability Leadership
CFS channels from recycled steel
vs. conventional precast systems
Life-cycle climate impact reduction
Key components
Connectors
Connectors secure the panels together, ensuring structural integrity and simplifying the assembly process. They reduce on-site labor and provide reliable support.
FRP Bars and Standard Metal Studs
Standard metal studs and high-tensile FRP bars are forged directly into the concrete. The result is a panel with a massive reduction in weight, but zero compromise in stability.
With and Without Insulation layer
Whether you choose a configuration with or without insulation, the exterior dimensions remain exactly the same. You get the thermal efficiency you need or the raw structural power you want—all within the same consistent, easy-to-install footprint.
Publications (Coming Soon)
Technical Whitepaper
Comprehensive analysis of our panel system technology
Technical Whitepaper
Comprehensive analysis of our panel system technology