The Tilt-Up Concrete Association (TCA) an international nonprofit organization that serves to expand and improve the use of Tilt-Up as the preferred construction method has announced the recipients of the 2010 Tilt-Up Achievement Awards.
In its 19th consecutive year, the Achievement Awards program was established by TCA to honor projects that use site-cast Tilt-Up concrete to introduce new building types, advance industry technology and provide unique solutions to building programs. Projects were reviewed by a panel of 15 judges representing a combination of TCA membership categories, educational institutions, publishing and industry management. Several judges worked collaboratively within companies to broaden the perspective and the experience base used to evaluate the projects. As in previous years, submittals were judged on aesthetic expression, schedule, size, originality, finishes and special conditions; all characteristics of the projects that would attract and hold the interest of architects and building owners. To qualify for consideration, projects had to be submitted by a TCA member in good standing from any membership category.
According to Jim Baty, Technical Director of the TCA, "This year's crop of projects once again demonstrates the unbelievable results that are achieved when creative design meets experienced construction."
Projects were encouraged from any market segment and were aligned into specific categories and sub-categories including Manufacturing/Industrial, Corporate Headquarters Complex, Warehouse/Distribution (Small Business/Distribution, Speculative), Retail (Life-style centers - Walking Malls, Single Occupant and "Big Box"), Office (One-Two Story, Three Stories and Higher, and Technology Centers), Spiritual Buildings, Educational (K-12 and Higher Education), Institutional (Detention/Correction, Low-Rise, Parking Garage, Service Facilities such as Hospitals and Care Centers), Commercial (Hotels, Golf Clubs, Recreation, Theaters, etc.), Housing, Special Projects and Innovative Application Techniques.
This year, the panel of judges recognized a total of 29 award recipients and selected six projects from across all categories that best represented the heights the industry has attained as Excellence in Achievement. These projects, detailed below, exemplify the current state-of-the-art achievement in Tilt-Up construction with their unique and inventive use of the Tilt-Up method.
One Haworth Center
300,000-square-foot office building and renovation in Holland, Mich.
Submitted by: Steinbicker & Associates, Inc. of Dayton, Ohio
Other TCA member involvement: Kent Companies
Products for this project supplied by: Meadow Burke
Intended to make a statement to their worldwide customers, the One Haworth Center renovation and addition was originally designed with a 54-foot tall cast-in-place concrete wall along one side of the portion of the building termed "the bookend." This unusual part of the building resembles a bookend because of its sloped and planted green roof, and tapered shape in plan. Up to 8 feet of this concrete wall is located below grade, supported on a cast-in-place retaining wall that forms one edge of an HVAC tunnel below the slab-on-grade. The design and construction team brought in an engineer with a specialty in Tilt-Up to facilitate the conversion of the cast-in-place wall to Tilt-Up; a value engineering conversion that ultimately saved the owner more than $200,000 and more than one month in the construction schedule. The original architecture incorporated reveals and form tie "cones" into the exposed finish for the cast-in-place walls; these elements were also cast into the Tilt-Up panels during construction. Other unique architectural features include full-height diagonal windows and a sloped top on the panels. While the window layout provides much architectural interest, it made the conversion to Tilt-Up somewhat difficult. The window layout dictated that some panels would be less than 3 feet wide at their base and more than 16 feet wide at the top, a panel geometry that would be unstable for erection purposes. For this reason, in several instances, multiple panels were temporarily tied together across the windows to create panels that could be erected safely. To accomplish this, temporary recessed horizontal concrete beams were added across the openings. These tie beams also acted to transfer the lifting forces from one side of the diagonal opening to the other, thus minimizing the differential deflections between the two sides of the panel during erection. Overcoming the effects of a full-height vertical depression in some of the panels, which reduced the structural thickness down to 5.5 inches, was the final challenge. This LEED registered building is classified as NC Gold by the U.S. Green Building Council.
Dexas International Building
175,000-square-foot warehouse/distribution facility in Coppell, Texas
Submitted by: Alliance Architects, Inc. of Richardson, Texas
Other TCA member involvement: Raymond Construction
Products for this project supplied by: Dayton Superior
The Dexas International Building, a single-story facility, houses the research, design and manufacturing workplace for a manufacturer of office and home organization products. The facility sits on a 12-acre tract of irregularly shaped land, which is located in an industrial park. The challenge was to utilize cost-effective construction techniques to create a design solution that reflected the client's reputation as a progressive, innovative company. One aspect that sets the building apart from surrounding structures is the unique approach to breaking down the scale of the large monolithic elements. To accomplish this, the team utilized panels of varying concrete thicknesses within individual panels. Load-bearing site-cast Tilt-Up concrete panels were used as the primary structural system. The architectural vocabulary expresses the panelized nature of the building's structural system, creating a distinctive identity for the client. The architect sought to maintain the expression of Tilt-Up panels as structured elements on the interior of the project by keeping panels exposed (where they would otherwise be furred) in lieu of drywall partitions. In addition, exposed concrete surfaces were partially clad in insulated drywall to improve energy efficiency. Unlike typical planning strategies for buildings of this type, offices were located at the "rear" of the property, taking advantage of views of a heavily wooded area. The building maximizes space, while providing generous loading aprons and employee parking areas. Trees and walled gardens also screen undesirable views of parking and loading docks on the adjacent property. At the front of the new headquarters, designers created a separate entrance to allow for a distinct identity for the occupants of a 40,000-square-foot lease space.
Sunlight Ranch Equestrian Barn
12,530-square-foot special project in Hobe Sound, Fla.
Submitted by: Woodland Construction Co., Inc., of Jupiter, Fla.
Other TCA member involvement: Permit Engineering Services, Inc.
Products for this project supplied by: Meadow Burke, White-Cap Building Supply, and Nox-Crete Products Group
Built as a hurricane-resistant, solid concrete structure, the Sunlight Ranch Equestrian Barn provides protection to its occupants in the event of a storm in the southern Florida region. During the construction of the exclusive equestrian community, the owner a long-time homebuilder in the area chose to use Tilt-Up to upstage the current method of construction, which uses wooden materials that would not withstand the damaging winds of a storm. The barn is an open-air structure that can be easily closed during a storm to offer optimal protection to equine occupants, which is a tremendous benefit to the horse owners. With an aggressive construction schedule accommodating the owner's commitment to new occupants, temporary casting beds were installed to provide an early start to the panel fabrication. They were done in two sequences due to limited casting space. The contractor was able to utilize Tilt-Up for the interior stall partitions to stabilize the structure. In addition, 3.5-inch demising walls were used between the horse stalls. The roof system utilized a truss/rafter system that rested on top of the Tilt-Up wall and was affixed using straps embedded into the concrete. To ensure the barn complemented existing structures on the campus, a panelized look was created using reveals and the facility was painted red. The use of Tilt-Up construction offered a unique selling proposition to attract tenants to the barn, which is 100 percent occupied. Further, Tilt-Up provides the long-term durability and low maintenance features that the owner desired. As the first Tilt-Up project of this kind in the area, the Tilt-Up contractor found an additional market for Tilt-Up where the industry can gain market share in equestrian barns throughout the country using this project as an example.
Bill Santucci Justice Center
114,000-square-foot civic facility in Roseville, Calif.
Submitted by: Buehler & Buehler Structural Engineers, Inc. of Sacramento, Calif.
Other TCA member involvement: Concrete Services
Products for this project supplied by: Dayton Superior Corp. and White-Cap Building Supply
Constructed to meet the court's needs for security, longevity, and durability in an economical system, this two-story building blends Tilt-Up concrete panels with stone, glass and metal to produce a noble civic presence. Judicial prominence is depicted through design, function, security and aesthetics. The innovative structural system relies on Tilt-Up concrete for the west, south and east sides of the building and allows nearly a full glass wall at the north entry side, which illustrates the transparency of justice. The Tilt-Up concrete layout provides lateral load resistance to seismic induced forces, while allowing an ornate glazed entry for the visiting public. In order to meet the blast resistance requirements, seamless, passive security measures were accomplished by integrating site structures, steps and pavement. The contractor achieved energy efficiency by using high thermal mass Tilt-Up concrete, as well as a high recycling content for reinforcing steel.
WPLG TV Station
75,048-square-foot office building in Pembroke Park, Fla.
Submitted by: Woodland Construction Co., Inc. of Jupiter, Fla.
Other TCA member involvement: LJB, Inc.
Products for this project supplied by: White-Cap Building Supply and Nox-Crete Products Group
Home to state-of-the-art digital broadcasting, WPLG-TV is the first station in the Southeast U.S. with high-definition digital technology in both the studio and the field. Their new facility reflects a linear element with strong vertical intersecting planes. Tilt-Up was selected for this project because of the complex design vision of the architect. By using Tilt-Up, the team was able to meet the design requirements within the budget, using the specified materials. Given the area's propensity for windstorms and hurricanes, it was critical that the news station remain operational during those events. Tilt-Up assured strong structural durability while still enabling schedule and cost restraints to be met. During construction, because of site constraints and lack of access to three sides of the building, 80 percent of the Tilt-Up panels needed to be constructed outside the building limits. This was done using three erection sequences, not including the satellite tower, to complete the 122 Tilt-Up panels on the small building footprint. Additionally, there were a large amount of recessed floor areas that were needed to accommodate numerous computer lines beneath the finished floor. A super flat slab for the studio and multiple lowered slabs for computer flooring were utilized. This was critical for the project to ensure that all the sophisticated high-definition broadcasting equipment could perform properly. Tilt-Up was also used for the 99-foot, 6-inch tall satellite tower, which represents a unique application of the Tilt-Up method. This was the most challenging erection sequence because the area available for the crane left no room to spare. It barely allowed for the size of crane needed to handle the weight and reach of these tower panels, while at the same time allowing enough access to set and weld the pieces. The tower erection also required extensive coordination between the ornamental steel and the Tilt-Up, as they were interconnected beneath the cantilevered sections of the upper tower. Winner of a number of awards (including one for Craftsmanship in Tilt-Up panel fabrication and one for crane operations), the marriage of architectural vision and durability provided the owner with a unique facility and added visual appeal.
Jumbo Luperon Shopping Center
550,900-square-foot retail facility in Santo Domingo, Dominican Republic
Submitted by: CCM of Santo Domingo, Dominican Republic
Products for this project supplied by: Meadow Burke
The Jumbo Luperon building, the largest in the Dominican Republic, has two levels of underground parking spaces with the capacity for 800 vehicles. The shopping center was built with cast-in-place concrete and elevated floors, as well as concrete columns and beams in both levels of parking. At one of the entrances, a combination of panels and spandrel panels were constructed for architectural reasons with some panels in cantilever. A gravity retaining wall tunnel was built utilizing Tilt-Up panels to resist land pressure and the truck loading dock. From the north-south direction, the use of counter fort panels, in combination with the steel roof deck, allow the building to resist Zone 3 seismic loads and Category 5 hurricane wind loads. The first level of the structure's roof support and beams were built in metal. The store area and first level of parking spaces were constructed on flat slabs, supported by cast-in-place concrete columns and beams. In order to cast these slabs, the entire area was sectioned off, simulating a chessboard formation, which allowed the production of induced joints beginning at the adjacent prefabricated panels. Because of the length of the floor, this chessboard formation allowed the contractor to build two floor levels without transversal expansion joints. Supported on a 20-gage galvanized steel slab, the roof of the building showcases a standing seam type supported on metallic purlings. The entire deck is loaded by steel joists which are supported by frames constructed with Tilt-Up elements as columns. The columns are coupled to the steel beams using bolted connections and a fiberglass insulated thermal layer is between each deck. To meet the client's requirements to avoid the use of asphalt waterproofing, this method was suggested by the contractor to prevent joint expansion from thermal changes. From a structural point of view, the standing-seam deck and the 20-gage deck work has a semi-rigid diaphragm that takes the lateral loads (seismic or wind) and transfers them to the metallic frames, working as elements of lateral load collectors transferring them to the sides of the column frames. Because of the longitudinal rigidness of the panels, the double metallic deck of the roof works as a redundant element in the transmission of the lateral loads in this direction. In addition to parking on the second level of underground space, a 40 x 155-foot tank is used to store water for domestic use and for the fireproof system of the project. Several panels on the sides of the tank were constructed to be used as a lateral load resistant element between floors. All the steel structure, Tilt-Up panels, precast and cast-in-place elements were 3D modelled using last generation BIM. This new tool used for engineering, planning and construction of this building demonstrates how quickly large projects can be accomplished using a fast track method.