The Tilt-Up Process
There are several benefits of concrete tilt-up construction such as fast track delivery, reduced costs, durability, and design flexibility. Newcomb Construction has been delivering high quality, innovative, designed concrete tilt-up buildings for over 30 years of our 45 year history. Although tilt-up is not new — it has been in use for well over a century — there are still many industry professionals not familiar with the process. Here at Newcomb, concrete tilt-up is delivered in these basic steps:
Form Tilt-Up Panels
Once the concrete panel design is completed by Newcomb’s in-house engineering staff, crews assemble the panel forms on the floor slab or casting slabs. Forms are usually created using standard lumber materials to serve as molds for the concrete wall panels. Each form defines the panel’s shape, size, openings for doors and windows, and bearing points.
Place reinforcement in Face Layer
The face layer serves as the exterior face of the panel. Workers tie in the steel grid rebar materials to reinforce each form, which adds to the structural integrity of the building. The face layer may also include façade inserts such as a brick, wood, or metal in-lay. Façade options are virtually unlimited and open the exterior design to highly innovative architectural features.
Pour Face Concrete
The face layer is ready for concrete pour. This layer is typically a gray or white color finish, however, color tints can be added to the concrete mix if desired. The face layer is typically 2 to 3 inches deep.
Lay Insulation & Insert Pins
Insulation panels are designed and sized to fit the panel form, placed over the face layer, and held in place with pin connectors that penetrate through the insulation panel into the face concrete. Insulation gives tilt-up structures true edge-to-edge insulation, offering greater design versatility, energy efficiency, and fire resistance.
Tie Structural Rebar
Consistent with the face layer, workers lay in and tie rebar steel inside the structural portion of the concrete panel assembly. Inserts and embeds are also placed in the structural layer at this time. These inserts are used to lift the panel, connect cross brace members, and attach structural footing and roof elements.
Pour Structural Concrete
The final concrete pour is the next step to complete panel assembly. The structural panel is typically 7-8 inches thick and will cure in seven to ten days.
Lift & Set Panels
The final step in the concrete tilt-up process is connecting to the lift points and lifting the panels into place by crane. Workers guide the panel into place, connect to the foundation wall, and secure temporary cross braces. Once all the panels are in place, the building is ready for the roof structure and completion of the building envelope.