Prestressed wall panels can typically be manufactured up to 14 feet wide and 50 feet tall, though transportation and crane capacity often determine practical limits. Panel weights generally range from 10-40 tons depending on dimensions and thickness. Your precast manufacturer can optimize panel sizing to balance structural requirements with handling and shipping constraints.

Panels connect through embedded plates, weld plates, and reinforced connections designed to transfer both gravity and lateral loads. Connection details are engineered to integrate with foundations, floor diaphragms, and roof structures while accommodating building movements and thermal expansion. Standard connection types include bolted, welded, and grouted options.

Fire resistance ratings of 2-4 hours are standard for prestressed wall panels, depending on thickness and concrete cover. Most building code requirements can be met without additional fireproofing. Specific ratings depend on panel configuration, with solid panels typically providing higher ratings than insulated sandwich panels.

Openings for doors, windows, and MEP systems are formed during casting for precise dimensions. Embedded plates and inserts for attachments are positioned during manufacturing based on project requirements. This eliminates most field cutting while providing connection points for cladding, equipment, and architectural features.

Manufacturing tolerances typically maintain dimensions within industry standards of ±1/4 to ±3/8 inch depending on panel size. Camber and deflection are calculated during design and controlled through prestressing levels. Erection tolerances follow PCI guidelines to ensure proper fit and alignment with adjacent building components.