Flexwall

Flexwall’s Role in Supermax’s Architectural Vision

On May 9th, 2024, PreCon’s technical sales representative, Joseph Albanese, met with architect Henry Chiu of Henry W Chiu Architect Limited to explore precast solutions for the proposed Supermax Healthcare Canada Facility at 329 Stirling Crescent, Bradford, ON. Following multiple discussions over several months, Henry Chiu concluded that the optimal choice was clear: Flexwall sandwich precast panels would best meet all the project’s building envelope requirements.

Henry Chiu recommended PreCon Precast to Supermax Healthcare as the preferred producer, highlighting that PreCon’s proprietary Flexwall precast sandwich precast offers appealing architectural aesthetics, cost-effective solutions with minimal structural steel, superior thermal performance, full compliance with OBC SB-10 requirements, and a streamlined construction schedule.

PreCon’s support throughout the project’s development and tender process ultimately led to a purchase order being issued by Innovative Structures Limited, the selected general contractor, on March 5th, 2025. The building’s design originally called for panels reaching 47 feet (10.325 meters) in height. The Flexwall prestressed system offered a significant advantage by eliminating the need for horizontal wind girts, thereby reducing the quantity of construction materials required.

True to its name, Flexwall once again proved its worth as the flexible material of choice when accommodating the atypical panel configurations at the building’s three curved corners. To emphasize the curvature at these corners, PreCon’s design—led by Anar Parikh P.Eng—incorporated segmented panels of non-standard widths, rather than the modular 2.4-metre Flexwall width. This approach enhanced and better defined the 10.750-metre radius at each of the three curved building corners. The facade further features horizontal strip lighting, surface-mounted directly onto the Flexwall panels, adding a sleek, modern accent to the building’s appearance.

Flexwall was also incorporated as a dado wall application at the “saw-tooth” loading dock, enabling seamless integration among the warehouse facility, the office, and the main entrances—once again showcasing the versatility of the Flexwall sandwich panel. During post-award meetings, PreCon’s engineering team deserves commendation for hosting several virtual sessions to ensure full coordination between the structural steel and the Flexwall precast façade.

In total, the project comprises approximately: 160 Flexwall precast units with pattern #4, covering 25,000 square feet of wall area, with a production duration of 24 days. Installation completed in 6 days.

Strategy: Smart Planning for Limited Access on the East Elevation

The east elevation, recognized as the building’s narrowest façade, presented a unique challenge due to a limited setback, an existing retaining wall, a drop in elevation to the existing Bell Easement, and a further drop on the east side of the retaining wall relative to street level. Under the leadership of Paul Davis, PreCon’s erection team developed a strategic plan involving the placement of a 220-ton crane in both the northeast and southeast corners of the property—effectively bypassing the restricted zone.

Timeline Summary

• Start of erection: November 19th
• Total Flexwall units installed: 160
• Duration of installation: 6 days

Read more about our next level construction projects in our newsmagazine Connections: Fall 2025.