SEMINAR REPORT-2013

TILT-UP CONSTRUCTION

1. INTRODUCTION
Tilt-Up is the technique of site-casting concrete walls or elements,
normally on a horizontal surface and then tilting them vertically into place.The term
Tilt-Up was coined in the late 1940s to describe a method for constructing concrete
walls rapidly and economically without the formwork necessary for poured-in-place
walls. It is a two-step process. First, slabs of concrete, which will comprise sections of
wall, are cast horizontally on the building floor slab, or separate casting slab. Then,
after attaining sufficient strength, they are lifted (tilted) with a crane and set on prepared
foundations to form the exterior walls. Although the method is most often called TiltUp, it is also called tilt-wall, or in specifications and technical papers, site-cast
precast concrete walls. However, Tilt-Up is the preferred and generally accepted
term. Precast concrete is a generic term meaning the fabrication of concrete building
components at a location other than their final position. Tilt-Up, while falling under the
category precast concrete, refers exclusively to site-cast wall elements. The term
Tilt-Up building refers to any type of building that employs the Tilt-Up technique for
constructing the walls.
The Tilt-Up wall panels typically weigh 60 tons or more, averaging only
6 to 8 in. thick. In Tilt-Up construction, formwork is only required for openings and the
perimeter therefore, very little formwork material is needed. When the wall panels have
attained sufficient strength, usually a week to 10 days, a mobile crane is brought to the
job site to lift and set them on prepared foundations. The erected panels are temporarily
braced and typically connected to one another.
The roof structure is then attached to the walls, the braces are removed,
joints are caulked, and the wall finishes are applied to complete the building shell. It is a
fast, simple, and economical method of construction, which has been used extensively
for one-story buildings and has most recently been adapted successfully to multi-story
structures. Today, walls of up to four stories in height are being cast and tilted into
position. Currently there have been several instances of wall panels as high as six
stories being cast and erected as a unit by the tilt-up method of construction. The
economy of tilt-up lies in its simplicity of construction. The critical factors in this

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method of construction are handled in the pre-construction planning stage. Skill in

laying out panel erection sequences and designing safe lifting elements which fully
utilize crane time will provide for the fast and safe
Tilt-up, tilt slab, or tilt wall is a type of building and a construction
technique using reinforced concrete. Descriptions of tilt-up construction abound
throughout history and some experts believe that tilt-up construction originated more
than 2,000 years ago when Roman architects discovered the ease of casting a slab of
concrete onto a graded ground surface and tilting it into position. It was in the early
1900s, when concrete was rapidly becoming the most popular building material, that
engineer Robert Aiken introduced the construction method now known as tilt-up
construction. Aiken was designing and building reinforced retaining walls at Camp
Logan Rifle Range in Illinois. Instead of using the traditional method of cast-in-place
concrete walls, Aiken poured the walls on a casting slab flat on the ground and tilted the
panels into position. Aiken then used steel rods to anchor the walls into the concrete
footing until the entire structure and roof diaphragm was in place. Aiken soon realized
that this building method would be advantageous if implemented correctly and used it
in several buildings throughout Illinois. The first complete tilt-up building was a
concrete factory near Zion City, Illinois.
Although tilt-up construction had been known for a long time, it was not
until the late 1940s that it really started gaining popularity with the introduction of the
mobile crane. The mobile crane facilitated the panel erection process and allowed for
larger panel construction. Ready-mix concrete also started to become available,
allowing tilt-up construction to become more efficient and cost effective.
These innovations could not have come at a better time. After World
War II, business in the United States was booming, subsequently increasing the demand
for commercial and industrial structures. Because tilt-up construction allowed
contractors to offer high quality projects at a cost effective price and with a reduced
construction schedule, the process quickly became increasingly popular. Since that
time, tilt-up construction has undergone many more innovations and refinements, and
has now developed into a building method commonly used by many concrete
contractors and general contractors in the construction industry.

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2. BENEFITS
Flexible finishes and architectural expression
Tilt-up panels can be plain and smooth or visually rich. Grooves, texture
and colour can be employed creatively by the architect, while plain-finished or
painted panels are used for a more subtle effect.
Financial gain
Tilt-up is highly competitive with traditional construction for a wide
range of buildings types. The inherent fire resistance and security of tilt-up may also
result in lower insurance premiums for owners and occupiers.
Tilt-up walls can be insulated economically to give the required U
values, from a normal building to cold stores. Sandwich tilt-up panels incorporate
insulation and minimise follow-on trades. This combination of concrete and
insulation builds into thermal mass which can reduce temperature fluctuations and
provide a durable internal and external finish.
Robust, easily-sealed surfaces
Tilt-up is sealed easily, making it ideal for controlled environments. The
low number of joints in a tilt-up building means exceptional air tightness is
achievable.
Significant sound and noise reduction
The mass of the concrete walls absorbs the sound rather than letting it
through as can occur with lighter forms of construction. Noise can be isolated within
a building and for airborne sound, tilt-up walls can provide a sound reduction index
of at least 52dB compared with about 20 30dB for lightweight cladding.
Fire resistance
Tilt-up panels can be designed easily for up to four hours resistance and
are particularly cost-effective as fire separation/compartment walls.

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Security
Tilt-up panels are frequently used for security walls and prisons because
they are virtually impossible to penetrate.
Fast programme to completion
A key benefit for using tilt-up is the fast programme to complete a
project. After the floor slab is placed, the typical elapsed time from starting to form
panels until the building shell is completed may be only four to five weeks. Materials
for wall panels are procured easily with minimal lead times, allowing a fast start to
this process, which progresses while any products with a longer lead-time are being
fabricated.
Health and safety
With a tilt-up building, much of the work is on the ground; there is no
vertical formwork, no scaffolding, and since the floor slab is poured first, workers
have a safer working surface.
Maintenance and durability
The wider panels minimise the number of joints and length of sealant,
thus reducing maintenance costs. Visual concrete (fairfaced, textured, profiled,
tooled and exposed aggregate finishes) and cast-applied facings (inlaid stone, brick
etc) require little attention, and modern paints have long life spans. Concrete
surfaces are resistant to mechanical damage, and are easily washed down.
Heat Insulation
Concrete mass in tilt-up panels not only slows down heat transfer, it also
stores heat during the daylight hours and releases it during the cooler night hours.
This translates in the need of less costly and more efficient heating and cooling
equipment. Tilt-up panels also provide for an excellent enclosure for passive solar
designs, because of the concretes heat storage properties.

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3. TILT-UP VS. PRECAST CONCRETE BUILDINGS

While they may seem similar, there are significant differences. The TiltUp panels are almost always load-bearing and do not require a separate structural frame
to resist service loads as architectural precast does. Full-height structural precast panels
dont require a separate structural frame, but are usually limited in width due to
transportation requirements. The precaster will frequently say he can build it faster,
because he can work in inclement weather and begin casting panels even before the site
work has begun.
Here are some factors to consider:
How far is the building site from the nearest qualified precaster for transportation
costs?
What is the widest, tallest and heaviest panel that can be transported?
Will the precaster use architectural precast, which requires a separate structural system
to resist service loads or heavier structural precast?
Due to travel limitations on width, there are approximately three times as many
precast panels to erect and brace and three times as many joints to fill.
Will the narrower precast panels accommodate the anticipated opening widths and
architectural pattern?

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4. TILT-UP VS. MASONRY BUILDINGS

Masonry, when compared with Tilt-Up, is generally more costly and
takes longer to build. However, in areas where Tilt-Up expertise is unavailable or where
masonry is inexpensive due to a plentiful labor source, you will see many masonry
buildings. However, enterprising contractors in these areas are introducing Tilt-Up and
often winning jobs that were first designed as masonry buildings. Faced with deciding
whether to use Tilt-Up or masonry, the answer you get depend upon who you ask. A
masonry contractor will tell you he can build it faster and for less cost, and a Tilt-Up
contractor will tell you his method is the better choice.
Here are some factors:
For a building of less than about 6,000 sq. ft., the choice is probably masonry, since
crane time is uneconomical for a small number of panels. And the limited floor space
may not be enough for casting panels.
For a large building in an area of the country where concrete blocks or bricks and
mason labor are inexpensive, it could be a toss-up, assuming Tilt-Up expertise and
cranes are available; if they are not, masonry wins by default. On a large project an
experienced masonry crew can work fast and very efficiently.
If a building has a high clear height inside, say over 24 ft., Tilt-Up is more economical
since the thickness of the wall required need only be increased incrementally, whereas
masonry jumps in whole block units, such as to 12 in. from 8 in.
For fire resistance, an 8 in. concrete block wall with all cells grouted is rated 4-hours,
equivalent to a 6. concrete wall. If the block wall is not solid grouted, it is rated twohours, which is equivalent to a 5 in. concrete wall
A concrete wall is generally denser and less porous than a masonry wall. With
masonry there is the problem of sealing and painting so water does not enter through
the joints, or through the blocks natural porosity. A Tilt-Up building is faster to erect
than a masonry building, given a relatively large building with repetitive panels.

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5. TILT-UP VS. METAL BUILDINGS

Metal buildings fill a market niche for low cost enclosures; however,
when they are designed to provide a similar level of performance comparable to a
finished Tilt-Up building, they can cost as much, and still lack the durability, fire
resistance, low maintenance, and other desirable features of a Tilt-Up building.
Recognizing the advantages of a concrete wall, some metal building contractors are
using Tilt-Up panels attached to the steel frame. The prefabricated, pre-engineered
metal building industry has aggressively marketed their product. They sell the concept
of economy through standardized manufactured components. You can almost pick your
building from a catalog. Metal buildings have their place for low cost shelter; however,
comparing features such as durability, maintenance, fire resistance, insulation, security
and others discussed above, there is little comparison. Additionally, a metal building
fitted for office use, with drop ceilings, finished walls, insulation, and other features,
can cost as much as a Tilt-Up building.
The metal building industry has recognized the advantages of Tilt-Up by
offering exterior walls of Tilt-Up concrete as an option rather than metal siding. Many
other countries have active and growing Tilt-Up markets, including Canada, Australia,
New Zealand, South Africa, South America and Mexico.

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6. THE TILT-UP TECHNIQUE-STEP BY STEP

Fig: 1 Tilt-up Technique

Onsite prefabrication of tilt up panels with face down on floor slab.

After attaining full strength the panels are tilted up using a crane.

The tilt up panels is placed over the prepared suitable foundations.

Joining panels and attachment of roof structure is then done.

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7. CONSTRUCTION STEPS

Foundation Construction

Floor Slab Construction

Panel Layout &Forming

Panel Structural Reinforcing

Wall Panel Casting

Erection of Tilt-Up Panels

Joining Panels &Structural Steel Frames

Deck Diaphragm

7.1 FOUNDATION CONSTRUCTION

The foundation system for a Tilt-Up building requires a few extra
considerations not encountered in a masonry, steel frame, or wood frame building. The
foundation system for a typical Tilt-Up building consists of interior footing pads to
support columns, interior continuous footings to support bearing walls, and the
perimeter footings or pads to support the wall panels. Wall panels are supported on
spread or continuous footings, See Figure 2.Spread footings are placed under joints
between panels, so that each footing pad supports one half of each adjacent panel and
the panel spans between footing pads.
Excavation for continuous footings is done economically with a trencher,
and little reinforcing is required. Whether a pad or continuous footing is used, the top is
held down about 1 in. below the bottom of the panels and this space is filled with grout
after the panels are up to provide full bearing on to the footing. For setting the panels at
the correct elevation, high density plastic shins or grout bearing pads are constructed on
top of the footings under the end of each panel. Customarily just one pad is used under
the joint between two abutting panels. These pads are about 1. In. high, set precisely at
the correct elevation (bottom of the panel), and are of a length sufficient to safely
support the weight of the panel until the grout is placed under the remainder of the
panel.

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Fig: 2 Panel Foundations

Following is the sequence most often used for constructing the foundations and floor
slab:
1. Prepare the sub grade for placing the floor slab. This includes possible importing of
fill material, compaction, installation of underground electrical and plumbing, and
excavation of the interior footing pads and interior bearing wall footings.
2. Place concrete for the interior footings. This includes setting the anchor bolts using a
steel plate template furnished by the structural steel fabricator.
3. Place, finish, and cure the floor slab.
4. Excavate and place exterior foundations. Sometimes this is done before the slab is
poured or at the same time.
5. Construct the leveling pads on the perimeter footings in preparation for setting the
wall panels. (At this point the wall panels are formed and cast.) Steps 4 and 5 can also
be done after placement of panel concrete, so concrete trucks can back close to head of
panel.
6. Place grout under the wall panels once they are up and braced for continuous bearing
onto the footings.
7. Place the closure strip between the exterior walls and the floor slab. This should be
done after the roof is in place but before the wall braces are removed.
8. Grout the base plates for the interior columns once they are up, then place concrete in
the blockouts.
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9. Check for excessively wide cracks or joints. Route, fill, and patch as required.
7.2 FLOOR SLAB CONSTRUCTION
The floor slab of a Tilt-Up building is especially important since it not
only functions as the floor surface for the life of the building, but also as a casting base
for the panels and a platform supporting construction equipment. Service loads during
the life of a manufacturing or warehouse building rarely exceeds 500 lbs. /sq. ft. and
usually does not exceed 100 lbs. /sq. ft., particularly in office buildings. Construction
loads are the heaviest loads applied to a Tilt-Up building's floor. These loads include
the weight of concrete trucks and the crane when lifting panels from the floor slab. In
contrast to service loads, construction loads can exceed 40,000 lbs. from the rear axles
of a ready-mix truck. Also important is the area over which these point loads are
applied. For example, a 5,000 lb. single wheel load from a forklift truck, using hard
rubber tires, may be supported on an area only8 in. wide by 2 in. long. In this case the
bearing area is only 16 square inches and the pressure under the hard rubber tire is over
300 psi, which explains why hard rubber tire forklifts are so hard on joints in a floor. In
contrast, the unit pressure applied by a ready mix concrete truck, or a pneumatic tire
forklift, will not exceed the tire inflation pressure, which may average 75 psi. The
pressure under crane tires can be as much as 150 psi.
Various steps in designing a floor slab include:
1. Determine what loads will be on the floor during its life, or at least the foreseeable
future. This may include steel storage racks, forklift trucks, palletized storage, stacked
goods, or other types of loads but not crane loads (addressed later).
2. Determine the required thickness of the floor slab.
3. Specify the concrete, including aggregate size, cement content, water-cement ratio,
28-day compressive strength, slump, and any admixtures.
4. Decide whether to include a granular base, and if a vapor barrier or retarder is
required.
5. Decide whether or not to reinforce the slab either with welded wire fabric (also
referred to as mesh) or reinforcing bars.
6. Select joint spacing.
7. Select type of joints to be used, as well as dowel sizes and spacing.
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8. Specify testing (quality control) requirements.

7.3 PANEL LAYOUT & FORMING
One critical task a Tilt-Up contractor performs during the planning stage
is panel layout and sequencing.
Variable factors affecting the layout process include the following:
Crane types and capacities available (including their costs)
The decision to lift from inside, outside or both
The ability to stack cast and where to use stacking as an advantage
If and how many temporary casting beds are required
Numerous design options are available for tilt-up construction varying
from project to project. In the design of a tilt-up structure, the panels themselves should
always be designed to withstand the in-place loads, lifting loads, and whatever features
that the wall will have. Architectural features such as color, finishes, exposed aggregate
or rustications should also be incorporated in the design. The designer should also take
into account the lifting inserts layout; usually it is done after all other aspects of the
design are complete. The following criteria should be considered when designing a tiltup panel:

Fig: 3 Window formed in panel

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Loads
A Tilt-Up panel is subjected to forces from three directions:

Vertical (downward) forces from loads imposed by roof or floor framing, and
from the weight of the panel itself, tend to cause the panel to buckle like a
column, or be overstressed in compression. The thinner the panel, the more
likely the tendency to buckle.

Lateral (sidewise) forces, from wind or seismic, tend to bend the panel. To resist
this bending, the panel spans like a flat slab between points of support, which
are usually provided by the floor and roof diaphragm. Alternatively, the panel is
designed to span horizontally between pilasters, but this is rarely done.

The third force acts in the plane of the panelparallel to itand tends to cause
the panel to shear, or slide on its foundation. In this case the panel acts as a
shear wall.

Resistance to all three forces is provided by the thickness of the panel and its
reinforcing. The forces that nearly always control the design, and determine the panel
thickness and reinforcing, are the lateral forceswind and seismic.
Panel with Openings
Panels with openings are becoming more and more popular. These
panels can be analyzed by finite element methods, but this is a very expensive and time
consuming process. An approximate analysis generally provides results that are
sufficiently accurate for most designs. Local codes should be consulted to meet
requirements. Where openings occur, the lateral and axial loads, including self-weight,
on the entire panel must be carried by the continuous vertical legs on each side of the
openings. If there is more than one opening, vertical legs should be able to carry all
loads. Often, it is only necessary to increase the loads acting on the legs by the ratio of
the total panel width to the leg width. Some designers may assume point loads are
exerted by door and window frames.
When the remaining panel width besides the opening is significantly
large, the width of the leg carrying the additional loads should be restricted to
approximately 12 times the panel thickness in design calculations. The use of a greater
width may fail to detect the danger of buckling. For very wide openings, it is
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recommended to design the panel legs or segments as beam columns extending the full
height of the panel. In some cases design loads may be substantial. Items to consider in
the design are:

segments and use of closed ties.

-of-plane forces
-plane shear and frame action
Since the panel reinforcement around the openings, and determined by
analysis, is often considerable, added crack control reinforcement may not be necessary.
Lifting Stress
As the tilt-up panel is picked up for erection, it is immediately subjected
to bending that causes both compressive and tensile stresses which must be resisted by
the panel. Manufacturers of inserts locate the picking points so that the overhanging
portions of the panel will reduce the bending moments between pickup points, therefore
reducing the compressive and tensile stresses in the concrete. The flexural stresses can
be determined by treating the panel as a beam supported by tension loads on the inserts
and the ground reaction. The gross concrete section of the panel is used as lifting
analysis. The load applied along the beam is the normal component of the panel selfweight. The tension and shear loads on insets vary as geometry in the rigging changes.
Maximum stress usually occurs at 0 degrees and between 30 and 50 degrees for two and
four row lifts. In the case that the allowable stresses are exceeded, additional
reinforcement, higher strength concrete, strongbacks, or another lifting arrangement
should be considered.

7.4 WALL PANEL CASTING

Good planning is a key part of all successful construction work, but it is
especially critical in tilt-up construction if all the cost, schedule, and safety benefits are
to be realized. Success of each construction sequence depends on the success of the

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preceding construction event. Successful construction of tilt-up panels requires careful

organization and planning.
It is recommended to check site access and the jobsite conditions as an
early step of construction planning. It is common for permits to be required by different
entities depending on the location of the jobsite. For example, special permits are
required for schools and churches since these are usually built in residential areas where
tonnage restrictions, noise abatement, and dust control regulations could exist. The
contractor and erection sub-contractor, if any, should determine site access and the
building access for the crane. Problems with uneven terrain or obstruction from other
construction trades should be noted and solved beforehand. Additionally, a suitable
location for crane assembly and rigging should be determined. Some local governments
will not allow this activity on public streets. In the early stages of construction planning
it is important to be aware of overhead wire problems.
Panel drawings can usually be found on the architects /engineers plans.
Complete panel drawings are essential. Plans should include panel identification,
dimensions, physical characteristics, reinforcing, location and identification of
embedded items, insulation, finishes and textures, and rigging and bracing information.
To insure an efficient construction procedure, consideration must be given to casting
location of panels and erection sequence. The contractor should develop a panel casting
layout, which can include temporary casting slabs or the floor slab, which will ensure
the most efficient casting and lifting of the panels. Panels must be properly located to
have efficient construction access and to minimize crane movement. Prior to panel
erection, it is important to watch for special bracing conditions, particularly at corners
and other interruptions of a straight building line. Cross-bracing will be required at the
corners, where braces will be required to pass either over or under the braces of the
previously erected panel. Avoid fill in panels where possible. It is recommended for
panels to be erected in a consecutive way were possible.
7.4.1 Casting Surface
The concrete floor slab is usually the most convenient place for casting
tilt-up panels. It is recommended for the floor slab to be placed as soon as possible as it

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used as the work table for all tilt-up panel forming, casting, bracing, and erecting. If
the floor slab is not available or there is simply not enough space available for casting
the panels, panels can be stack-cast one on top of another or in a temporary casting
platform or casting bed on an accessible location outside of the building. The floor slab
must be level and smoothly troweled for a high quality finish. A smooth surface is
important to prevent mechanical bonding and is necessary for clean cleavage when
lifting. A properly constructed floor slab should have a compacted subgrade with
adequate strength and thickness to carry the loads of material trucks and heavy mobile
cranes that may be needed in the erecting process. Floor slab jointing should be located
between panels whenever is possible. If the floor contains openings for pipes or other
utilities, a -inch skin coat over sand fill can be used to close up the openings
temporarily.

Fig: 4 Casting Slab and Tilt-Up Panels

7.4.2 Edge Forms

One of the advantages of tilt-up construction is the savings in form
material and labour. Panel edge forms, which are a relatively easy form to erect, should
be securely bolted or weighted down to the casting surface. Top and bottom edge forms
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need to be braced and squared. A recommended method for securing panel edge forms,
is to make L-shape forms on the site or use prefabricated steel angles, then anchor them
to the floor slab by drilling 3/8-inch holes through the forms (prefabricated steel angles
should already have these holes) into the casting slab, and anchored with double headed
form nails wedged into the hole in the concrete. Using pieces of plastic wedged
between the nail and the concrete also facilitates the stripping of the forms when
removing the nails from the casting bed. Holes can be patched with epoxy at
completion of the work.
In constructing panel forms it is important to avoid variations in form
measurements and insure a good straight line in the panel sides and from panel to panel.
It is recommended to use a chalk line for laying out the forms, and spraying a sealer
over the chalk so weather will not wash the lines away.

Figure.5: Tilt-Up Panel Forms

Slight variations in form measurements will result in plumpness
variations and will affect joint dimensions.
Windows and door openings in panels are usually not a problem to form.
The common method used by contractors of including windows or doors in a tilt-up
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panel is to cast directly against the steel sash or frame. All opening forms should be
held down on the casting slab with either weight or by the method described above.
Exposed surfaces of sash or frame should be given a coat of bond-breaking compound
to prevent concrete adhesion.
7.4.3 Bond Breakers
A good bondbreaking agent is also essential in tilt-up construction to
obtain an easy lift from the floor slab. There are three basic bondbreaker types.

Synthetic petroleum, hydro-carbon, resin solutions

Solutions of waxes with metallic soaps

Solutions of organic esters and silicones

It is important to be aware of some of the effects each bondbreaker

might have on the final appearance of the panels. For example, some bondbreakers
leave residue, especially when applied excessively to the casting surface. Residues
affect the coloration of the panels and can prevent adhesion of paint, adhesive, sealers,
or any other treatments. If the possible effects of the bondbreaker on the panels are
unknown, it is recommended to consult the manufacturer before using it.
It is very important to test the bondbreaker agent with the curing agent
for compatibility, usually before casting the slab. The bondbreaker coat should be
applied prior to placement of the reinforcing steel. Care should be taken to ensure that
the bondbreaker is not sprayed over dirt, sawdust, dew, frost, or surface water. An easy
method for testing separation is to sprinkle water on surface were the bondbreaker was
applied. If the water beads as on a newly waxed floor, the panels will separate. If the
water is immediately soaked into the floor, the panels need re-spraying. Bondbreakers
that have been heavily exposed to rain or to weather for longer than three days should
be checked. Re-spraying might be necessary. Bondbreakers not applied correctly will
result on panel surfaces that stick. Not being able to separate the panels can result in
damaged and cracked panels, pull out of lifting inserts, or exceed crane load capacity
creating schedule delays and panel re-construction costs.

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7.5 PANEL STRUCTURAL REINFORCEMENT, INSERTS & EMBEDMENTS

Having the reinforcement in the right location, in the right sizes and the
right quantities, is essential for the structural integrity of the panel during its service life
and for stresses that can occur during lifting. In addition to the reinforcement, a number
of other items must be cast into the panel. These include lifting inserts, wall brace
inserts, anchor bolts, beam connections, weld plates, and other items necessary for
connections to the panels. Embedments consist of beam pockets, support angles, plates
for attachment of structural components, and other items that are an integral part of the
panels after they are erected.
(Note the term embedments is used to indicate items embedded into the concrete.
The term embedments is also used and means the same, but the former is more often
used.)

Fig: 6 Panel Reinforcement

Around openings, reinforcement bars are added to strengthen the corners
and edges. In the locations were wire fabric is the principal reinforcement, dowel bars
should be provided where panels and columns are tied together. To provide for clear
cover, mats of reinforcement should be lowered onto plastic chairs. Chairs made of
steel wire should have plastic tips.
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Fig: 7 Panel Reinforcement

7.6 INSULATION
There are a number of options for insulating tilt-up panels but the most
economical method is to cast normal weight concrete directly over rigid, low density
insulation which is laid in the form. Panels constructed this manner have to be cast face
up with lifting inserts located on the outside surface. Another method is to install
insulation panels or apply insulation directly to the inside wall surface after placing the
wall panel in a vertical position.
A wall panel of sandwich construction is preferred for many buildings.
Sandwich panels consist of two wythes of reinforced concrete bonded together to a core
of rigid, low density insulation. Sandwich panels can be load bearing or non-load
bearing. It is common for sandwich panels to consist of one layer of structural concrete
and the other of lighter-weight architectural concrete. The concrete layers help provide
thermal mass. That is, the concrete is able to store significant amounts of thermal
energy and delay heat transfer through the building walls. According to the
Fundamentals Handbook of the American Society of Heating, Refrigerating and Air
Conditioning Engineers, Inc. (ASHRAE), this delay leads to three important results:

Slower response time tends to moderate indoor temperature fluctuations under

outdoor temperature swings.

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In hot and cold climates, energy consumption is significantly reduced over that
for a similarly sized low mass building.

Because the mass is adjacent to the interior of the building, energy demand can
be moved off-peak periods because energy storage is controlled through correct
sizing of the mass and interaction with the HVAC system.
The first step in sandwich panels is to pour and level the exterior layer of

concrete. Then the insulation panels or sheets are arranged on top of the unhardened
concrete according to the individual panel drawings. The insulation panels can be prefabricated and pre-drilled by the manufacturer. Connectors are inserted through the
insulation sheets. Most connectors are made from a fibre composite material. In the
past, it was common to use steel to hold the panel together, but testing has proved that
fiber composite connectors are better suited for sandwich wall construction because
steel conducts heat energy at a rate over 50 times greater than that of fiber composite
ties.

Fig: 8 Panel Insulation

7.6.1 Thermomass Fiber Composite Connectors
The connectors hold the wall together by developing a keying action
within the concrete wythes using specially designed notches. Connectors provided by
Thermomass (See Figure 9) have been tested to have pull-out capacities in concrete

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exceeding 5,000 lbs., shear capacities as great as 2,500 lbs. each, and a tensile strength
up to 140,000 psi.

Fig: 9 Thermomass Fiber Composite Connectors

7.7 CONCRETE PLACEMENT AND CURING
The concrete is placed the same way as the floor slab. Care must be
taken to prevent rock pockets along the bottom of the edge forms and to prevent
damage to the bondbreaking material. Concrete must be properly consolidated using an
appropriate vibrator. Avoid any contact between the vibrator head and the casting slab;
this will affect the bondbreaking surface resulting in lifting problems. Additionally, it
can damage the appearance of the exterior surface.
7.7.1 Layout, Alignment, Leveling, Bracing and Connecting
Prior to erection the panels should be labeled for identification, laid out
on the exterior foundations, and establish the exterior wall line. A commonly use
method of alignment requires the contractor to mark the limits of each panel and drill
-inch holes into the foundation approximately 5-inches deep. Then install #5 dowels,
two on each side of the panel. This process is helpful when placing the panels as it
reduces the effort in keeping the panels aligned. The day before erection of the panels,
install shims using a level to avoid placing the panel in a tilted position and more
importantly setting the panels at the wrong elevation. A simple and commonly used
method is to set up the shims to a desired or specified elevation below finish floor or
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grade. After panels have been erected, it is important to backfill and compact the
perimeter strip. The perimeter strip is a 3ft to 5ft wide and 4ft to 6ft deep strip at the
edge of the finish floor. After backfilling, grout is used to fill the voids between the
panels and the finish floor.
Bracing should be done prior to erection of the panel. Bracing done after
erection and while the crane is holding the panel in position is a costly procedure as it
requires the use of additional equipment such as lifts or temporary scaffolding.
Additionally, it places personnel in a hazardous position. Figure 10 above illustrate how
complex the bracing layout can be on a given project. The braces should be adjustable
and positively anchored to imbedded inserts of sufficient strength to resist both
horizontal and vertical forces acting on the panel. The angle between the brace and the
finish floor should be between 45 degrees and 60 degrees, all connecting bolts must be
checked to ensure tightness and prevent movement of the braces.

Fig: 10 Complex Bracing

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7.8 ERECTION OF TILT-UP PANELS

Erection of the panels is a critical phase during tilt-up construction. It is
imperative that the designer, contractor, and usually an erection sub-contractor plan and
check all rigging and tilting procedures carefully to ensure that the tilt-up phase is done
safely and efficiently. Not planning for erection and not taking the necessary safety
precautions can be fatal.
The correct crane should be selected prior to construction and based on
the panel design. The general rule for sizing the crane is that the crane capacity should
be a minimum of two or three times that of the heaviest panel including the weight of
all the rigging gear. In addition to the general rule for sizing the crane, the American
Concrete Institute recommends the following three questions to be answered before
determining the crane size:
1. How far must the crane reach to lift the panel?
2. How far will the crane have to travel with the panel?
3. How far will the crane have to reach to set the panel?
After selecting the correct crane, alternative crane positions should be
considered to make the erection phase as efficient as possible. When the wall panels are
to be erected before construction of the structural frame or roof diaphragm, it is
recommended that the crane operates on the floor slab. If this is the case, panels can be
formed and casted beside each other in rows or stack-casted to allow a substantial
amount of panels to be erected while minimizing crane movement. Before rigging the
contractor should provide clean working area and the panel should be cleaned of all
debris and loose tools.
7.8.1 Rigging
An even number of lifting points is recommended unless panels with special shapes
require different rigging procedures like some sort of automatic equalizing system is
being used. Panel erection should be done in a continuous and smooth motion to avoid
overloading. It is important to make sure that the bottom section of the panel is not
dragged on the casting bed or ground during erection, as this can damage the panel.
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Fig: 11 Panel Erection

It is important to use wedges and pry bars to help release the panel.
Panels stuck to the casting bed can double the load on the pick-up inserts causing
possible withdrawal. As lifting starts and cables start to get tensioned, they will
inevitably try to rotate. A rope can be used to prevent undesired rotation and to keep the
panel aligned. Ropes should also be used to prevent braces from getting trapped by the
rigging when the panel is being set in its final position. Braces that get trapped can
damage the floor slab or cause the insert to snap, permanently damaging the panel.
7.8.2 Placement
If it is a closure panel, measurements should be taken prior to lifting the
panel to make sure it will fit correctly.
` A theodolite can be used to fine tune the final panel plumbness by making
sure the panel is in a 90 degree angle with the floor. All pipe braces are designed to
have threated adjusting units; this can be used to position the panel as plumb as possible
even after the braces have been attached to the floor.
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Fig: 12 Panel Placements

7.8.3 Temporary Bracing

Once the panels are erected in place, tilt-up panels must be temporarily
braced against wind loads and other lateral forces until all final structural connections
are completed. The most commonly used method for bracing tilt-up panels is the use of
telescoping pipe braces.
7.9 JOINING PANELS
Panels are joined end to end with only a narrow joint between them,
which is caulked for water tightness. The precision to which panels are set is such that
there is rarely more than 1/8in. variation in thickness along the length of the joint.
When a wall must be fire resistive, there are joint fillers available that give two-, three-,
and four-hour fire wall ratings. Choice of the joint filler is important since it must
remain relatively flexible to accommodate the expansion and contraction of the wall
and adhere properly to the concrete to insure its water tightness. Structural connections
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between panels are usually made by welded chord bar splices, or splicing the steel
ledger, at the roof line. This type of connection affects a continuous tie along the length
of a wall for resistance to lateral forces imposed by the roof and floor diaphragms. In
areas of low seismic risk the structural ties between panels are sometimes omitted. In
the earlier days of Tilt-Up the panels were joined by poured-in-place concrete pilasters
or stitch joints. In this method, which is rarely used now since it is more costly and
often resulted in cracking, a one-foot gap is left between panels and the horizontal wall
reinforcing projects into this gap. Concrete is then placed to make the closure.

Fig: 13 Common panel joint with backer and rod partially placed

7.10 ROOF DIAPHRAGMS

A horizontal diaphragm is used to transfer lateral (wind or seismic)
forces to bracing elementsusually the end walls of a building. They are considered
either flexible or rigid; the former being plywood or metal decking, and the latter being
concrete. A diaphragm can be thought of as a plate girder on its side, spanning between
vertical shear resisting elements (usually shear walls), with the web of the girder
(sheathing, plywood or decking) resisting shear and the flanges (chords) resisting
tension and compression.After erecting all panels and completing the roof structure, it is
recommended to install backer rod, spray water-proof foam and then seal and caulk all
wall panel joints. If the panels are not to be painted, a cleaning agent and a sealant can
be used to provide protection.

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8. FINISHING AND ARCHITECTURAL TREATMENTS FOR

TILT-UP PANELS
A wide range of colored coarse aggregates and sands, several possible
colors of cement, and many other architectural available applications offer an owner
and designer an array of possible colors and textures which can be applied to tilt-up
panels. In the United States there are four or five commonly used methods for obtaining
various finishes on tilt-up panels. These methods include exposed aggregate that is
usually obtained by sandblasting, the seeding method, the sand bed method, and
finishes obtained by using a textured liner. Decorative patterns and even stone-face can
also be added to obtain the desire design.
8.1 EXPOSED AGGREGATE FINISHES
Sandblasting
The main classifications for sandblast finishes are light blast, medium
exposed aggregate, and to fully exposed aggregate. This can be obtained by varying
from fine to coarse sand and applying various pressures. It is recommended to sandblast
the face-down of a panel because a higher concentration of aggregate, as gravity tends
to move aggregate towards the bottom. Additionally, the face-down surface does not
have any lifting or bracing inserts which are very difficult to patch in order to match the
surrounding surface. The most commonly used finishes are light to medium exposed
aggregate. The reason for this is that concrete in the panels has to reach sufficient
strength to avoid creating stress and bending cracks when tilting the panels. Most
contractors allow the concrete to reach at least 3000 psi before tilting, while normal
sandblasting should be done before the concrete reaches 1500 psi to 2000 psi, heavy
sandblasting is required making this a more costly operation.
Seeding Method
To create the desired exposed aggregate finish, the aggregate can be
either seeded over the fresh concrete or hand placed on a wet mortar. The method
chosen typically depends on the aggregate size. To accomplish this, a structural
concrete mix can be poured in the forms and consolidated to a level of 1/8-inch to 7/16inch below the desired finish which allows for the volume of the selected aggregate to
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be seeded. Once the structural concrete has been screeded to the proper level and
consolidated, the aggregate is seeded carefully by shovel or by hand to completely
cover the concrete layer.
Sand Bed Method
The sand bed method is recommended when the aggregate selected for
exposure is 1-inch or more in diameter. This includes large field stone materials. The
two most common methods of utilizing the sand bed method to expose aggregate are:
(1) Place the aggregate on the casting bed and sprinkle sand between the aggregates
(2) Spread a layer of fine sand over the bottom of the form and then imbed the
aggregate.
8.2 TEXTURED LINE
A variety of patterns may be produced in large tilt-up panels by using
plastic materials as form liners. Common liners used are vacuum-formed
thermoplastics, fiberglass-reinforced plastics, or plastics formed into shape by heat and
pressure. Some advantages of using this method is that liners can eliminate the extra
care of preparing the casting bed so that joints, cracks, block-outs, etc will not be
reflected in the panel. Liners also provide a wide range of textures and appearances.
Finishes obtained with liners include simulated sandblast, ribbed finishes, boarded
textures, bush-hammered finished, and many more.
The use of liners in tilt-up construction is usually limited to larger
projects where higher utilization of liners can be obtained. Liners are expensive and
usually require a minimum of three to four uses to be economically comparable with
other finishes. An important aspect to consider is that plastic does not bond to concrete,
so parting agents are frequently not needed.

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Fig: 14 Textured Cedar Ridge High School, Austin,

Texas

Fig: 15 Cedar Creek High School, Austin, Texas

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Fig: 16 Liner at Charlie Rouse High School, Austin, Texas

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9. CONCLUSIONS
Tilt-up construction has been around for a long time, but it was not until
the late 1940s that it really started gaining popularity with the introduction of the
mobile crane. Since then, tilt-up construction has undergone many innovations and
refinements, and has now developed into a building method commonly used by many
concrete contractors in the construction industry.
In the design of a tilt-up structure the panels should always be designed
to withstand the in-place loads, live loads, wind loads, and most importantly, lifting
loads. The designer should take into account the lifting inserts layout and all
architectural features incorporated into the final design of the structure.
Good planning is the key part to all successful construction work, but it is
especially critical in tilt-up construction if all the cost, schedule, and safety benefits are
to be realized. It is important for the contractor to develop a panel casting layout to
ensure the most efficient casting. The floor slab can be used efficiently as the work
table for panel forming, casting, bracing, and erecting. The lifting or erection of the
panels is a critical phase during tilt-up construction. It is imperative that the designer,
contractor and usually an erection sub-contractor plan and check all rigging and tilting
procedures carefully to ensure panel erection is done safely and efficiently. The correct
crane should be selected based on the panel design. A wide range of colored coarse
aggregates and sands, several possible colors of cement, etc available offer an array of
possible colors, textures, and finishes that can be applied to tilt-up panels.
In

conclusion,

tilt-up

construction

basically

involves

job-site

prefabrication of concrete building members under controlled and relatively economic

conditions. Tilt-up construction is generally identified with industrial and commercial
building, but has been increasingly been used in other types of buildings such as
parking lots, residences, shopping centres, and churches. It is important to recognize the
opportunities and advantages tilt-up construction has to offer. Even though tilt-up is not
a new idea, it has been proven to be one of the most efficient and cost effective
construction methods known to date.

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