Tilt-Up Concrete Association Announces Winners of 23rd Annual Achievement Awards

The Tilt-Up Concrete Association (TCA) – the global authority for the tilt-up industry – has announced the recipients of the 23rd Annual Tilt-Up Achievement Awards.

The Achievement Awards program was established by TCA to honor projects that represent an increasing diversity of building types constructed with site-cast tilt-up concrete as well as those that advance industry technology, apply innovative form and provide unique solutions to building programs. 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 those skeptical of the potential as well as challenging experienced professionals to broaden their ideas for potential. Ultimately, the competition is designed to raise awareness not only of the effectiveness and maturity of the market, but also the professional experience of TCA members throughout the world.

The judges for the competition represent a combination of TCA membership categories, educational institutions, publishing and industry management. Additionally, this year the TCA’s social media fans chose three projects as fan favorites. The fan favorite selection was open to everyone and was a separate process from the formal scoring process completed by the judges’ panel.

This year, the panel of judges recognized a total of 31 award recipients, and selected 11 overall Excellence in Achievement winners that best represent the heights the industry has attained. These projects, detailed below, exemplify the current state-of-the-art achievement in tilt-up construction with their unique and inventive use of the method.

The projects winning this distinction are noted below.

Tooele Applied Technology College: 73,751-square-foot educational building in Tooele, Utah. Submitted by: Hughes General Contractors of North Salt Lake, Utah.

EXCELLENCE WINNER | The Tooele Applied Technology College is a higher education facility, half of which was constructed with tilt-up, the other half of which was constructed with a steel frame and brick veneer. To certify the cohesion of these methods, the contractor ensured the footings of each half were properly proportioned so everything matched up with the building line. The facility’s tilt-up portion was meant to appear as though it were cedar wood. To accomplish this, the contractor used unique tilt-up form liners, which were rough and jagged to imitate the appearance of boards. Whereas tilt-up panels are usually a uniform thickness, the panels for this project were uneven and had tapered, beveled edges. To preclude a perceptible difference of depth between concrete produced from separate form liners, the contractor provided an innovative solution by shaving off parts of the concrete to create, between for liners, smooth transitions that emulate rough sawn lumber. The building makes extraordinary use of natural light. It is equipped with ample windows, skylights in the bays and a clerestory. From the inside, the ceiling looks layered. Above the receptionist's area, the ceiling is lower than in others and curves along a specific radius. To achieve this design, the contractor used heated angle iron. Tooele Applied Technology College demonstrates that a structure composed largely of tilt-up concrete can have a light, airy, modern and comfortable feel. With high-end finishes and extraordinary attention to detail, the tilt-up complements a multitude of distinctive materials, all of which are symbolic to the community. These materials include reclaimed wood from the Great Salt Lake, corrugated metal panels, mineral rocks, hanging pendant lights and native landscaping. The board-form tilt-up, which resembles the boards of a barn, is a symbolic nod to the area’s agricultural influence. The building not only accommodates the highly technical equipment necessary to train students in diverse fields of expertise, it represents the community's rich history and culture through the manifold materials with which it was constructed.

EagleBurgmann: 26,802-square-foot industrial building in Houston, Texas. Submitted by: Powers Brown Architecture of Houston. Other TCA member involvement: Pinnacle Structural Engineers and Textured Coatings of America.

EXCELLENCE WINNER | FAN FAVORITE | This project for a German holding company’s American division had the objective of capitalizing on its proximity to a major well-traveled highway to increase the company's presence and brand. The existing facility was a functional single-story industrial box with mezzanine that facilitated the manufacturing and testing of valves. The consolidation of the off-site management arm of the company combined with office space for a recent acquisition had to be seamlessly combined to form the new headquarters. While large enough to accommodate the two-story office addition, the site simply could not also accommodate required parking. Thus, a vertical building allowed for the iconographic expression and the flexibility to seam into the mezzanine level of the factory. To meet aggressive budget and schedule constraints, the architects redesigned this project from conventional construction to the first four-story tilt-up project in Houston with no reduction in aesthetic appeal. The addition’s lower levels include training and vendor spaces on the ground, with factory operations and engineering at the second level, spanning both the new and existing footprints. The new tower offers executive spaces for both divisions with concomitant support spaces. The tower is integrated with the lower factory building with a vertical/horizontal transaction zone – a knot of circulation allowing the floor-to-floor heights at levels one and two to calibrate through soft ramps. The tower’s skin is designed with solar orientation in mind. The north-facing facade, behind which the open-office areas are located, is clad in high-performance curtain wall, while the direct west-facing elevation is punctuated with punched openings that directly index the proportions on the factory building. Most of the closed office spaces reside on this side. Each of the upper office tower levels has a curved balcony for the executive offices use. A small footprint and a vertically oriented building required precision in construction sequencing and complex bracing strategies. Highly recognizable and visible, the EagleBurgmann facility demonstrates the successful use of multiple tilt-up techniques, including spandrel panels, ribbon windows and punched openings.

Quala Republica Dominica: 222,234-square-foot industrial project in Haina, San Cristobal, Dominican Republic. Submitted by: Contratistas Civiles y Mecanicos (CCM). Other TCA member involvement: Meadow Burke and Nox-Crete Products Group.

EXCELLENCE WINNER | The architect wanted to use white concrete in exterior tilt-up panels. Some exterior panel surfaces were built with white concrete and the aggregate exposed. The manufacturing area was designed using ventilation with roof thermo siphons and natural light with concrete, custom-made skylights. The entire structure was built in concrete (walls, columns, beams and roof). The windows were also built in concrete (prefabricated lattices). Tilt-up panels on the south side were designed to be removed for a future expansion. The primary load-bearing structures (columns and beams) were built with the same concept of tilt-up panels (prefabricated in-situ and hoisted). This project demonstrates innovation with the use of white concrete, the use of concrete in all of the structure, shell and finishing elements. It features an innovative surface finish with exposed aggregate. This project provided a great source of employment to the community and has increased the value of land in the area. The design of the project – with natural ventilation and natural light – decreased electricity use by almost 100 percent. With the tallest panel of 50 feet, 10 inches, and widest panel measuring 30 feet, 3 inches, the project’s 160 panels cover a wall area of 85,878 square feet. The heaviest panel weighs 108,270 pounds.

Saint Louis Art Museum New East Building: 215,000-square-foot municipal project in St. Louis, Mo. Submitted by: Fenix Construction Company of St. Louis. Other TCA member involvement: Meadow Burke, HD Supply White Cap, Nox-Crete Products Group and Thermomass.

EXCELLENCE WINNER | The tilt-up panels on the new East Building were constructed using many non-typical methods and feature many unique qualities. The final finish of the panels has a look similar to granite. Achieving this effect required grinding ½ inch of material from the finished face and polishing of the panel prior to erection, highlighting the profile of the various specialty aggregates used. To perform the grinding and polishing prior to erection, the panels had to be cast with the finish face up, meaning all lifting inserts were installed on the exposed face of the panel and had to be patched to match the surrounding finish. In addition, multiple panels at the building’s corners have 90-degree return legs which were cast monolithic, requiring ½ inch of material to be saw-cut from the finished face to expose a cross section of the aggregates. Additionally, no joint sealant was used and because there is by design a ¾-inch gap between panels, the panels were poured oversized and cut to exact dimensions to reveal the aggregate cross section on all sides to maintain uniformity. Another unique architectural feature of this project was the setting and attachment of the panels to the building itself. The panels act as the building facade around the ground floor of the East Building and are not set on a footing or foundation but are instead attached to the structural steel of the building, making them appear to be floating. Complicating this process further is the fact that the East Building is set atop a two-level underground parking garage. As the weight of a crane could not be imposed upon the concrete garage, the use of a 550-ton Grove GMK7550 truck crane with mega-wing attachment was crucial, as it enabled the panels to be hoisted without the crane being placed on the existing garage. The Saint Louis Art Museum was awarded Gold LEED Status by the U.S. Green Building Council (USGBC) for the new East Building.

1242 Fourier Drive: 28,533-square-foot office project in Madison, Wis. Submitted by: Newcomb Construction Company Inc. of Madison.

EXCELLENCE WINNER | Using concrete tilt-up construction, this 28,533-square-foot, two-story office building was created at a cost of less than $100 per square foot, including site-work and interior build-out. The second floor is occupied by the district offices of the Internal Revenue Service (IRS), and the lower floor is to be used by a medical services company. The plan is configured to allow multiple tenant suites along a single loaded corridor on each floor. The exterior construction materials are brought into the interior through the use of exposed structural steel, sandblasted concrete walls and polished concrete floors. Finish colors are derived from the sand and stone aggregates within the concrete, using earth tones characteristic of the Midwest. This common access area is generously illuminated by northern light and provides welcoming space at the front door of each tenant. This feature is especially appreciated by visitors to the IRS. On the exterior, the generous canopy of the entrance hall projects the significance of the public space within. The exterior of the tilt-up walls features either common face brick or integrally cast concrete. The 12-inch-thick wall section is expressed on the ground floor by deep-set window openings, while on the upper floor, flush butt glazing conveys the continuity of the open office spaces within. Brick in stacked bands of contrasting texture references stratified limestone road cuts and outcroppings of the region, helping situate the building visually in its place. The project included the IRS’ required safety and security requirements, all at less than $100 per square foot. Tilt-up construction has proven to be an attractive and affordable solution to the project’s needs. This project has been certified LEED-CI Gold.

Chico’s National Store Support Center (Building 10): 50,515-square-foot office project in Fort Myers, Fla. Submitted by: Woodland Construction Company Inc. of Jupiter, Fla. Other TCA member involvement: Meadow Burke, Nox-Crete Products Group, Textured Coatings of America and Permit Engineering Services.

EXCELLENCE WINNER | The new Chico's corporate office building (Building 10) is located on the National Store Support Center (NSSC) 60-acre campus. The facility houses Chico's human resources, technology, e-commerce, store design and construction departments. The size and appearance of Building 10 stands out as the only multi-story building on the campus, which required an almost flawless finish. With this goal in mind, the owner chose tilt-up construction for its fast-track abilities and architectural flexibility. Building 10 boasts many unique architectural features – most prominent is the exterior design. Exterior building features include cantilevered members, tapered panels and compound shapes used by the designer for appeal. The shell system and tilt-up panel finish were designed to remain unfinished and provide an exposed concrete look for the majority of the building's skin. Nearly all tilt-up panels were coated with a clear sealer, which required a flawless panel finish without any marring or scars and with minimal appearance of form lines. A total of 113 tilt-up panels were used on the 90,466-square-foot wall-panel surface area. Tilt-up panels were as tall as 59 feet, 11 inches and as wide as 34 feet, with the largest panel weighed 171,850 pounds. Working with the client's vision, the architect included conical reveals (snap-tie cones) throughout the panels that did not have linear reveals. This required that the spacing and alignment be precise and align accordingly with all adjacent panels. Precise layout of erratic, random linear reveals was required in order to ensure the stair tower reveals aligned with adjacent panels, and close coordination among all design team members was necessary to ensure alignment. Chico's National Store Support Center, Building 10 was praised locally for its fast-paced erection and creation of more than 400 new jobs in Lee County. The project was also applauded by the Lee County Development District and Governor Rick Scott's office. Building 10 is currently pending Silver status by the Florida Green Building Coalition (FGBC).

Dalchau Service Center Building D: 78,952 square-foot office building in Austin, Texas. Submitted by: American Constructors Inc. of Austin. Other TCA member involvement: Meadow Burke, White Cap and Dayton Superior.

EXCELLENCE WINNER | The Dalchau Service Center Building D was constructed for the Lower Colorado River Authority (LCRA) to house various engineering departments. This building is a three-story, 78,952-square-foot structure providing Class A office space and multiple conference rooms with integrated audio/visual systems. Early in design, tilt-up was selected, as it was decided to incorporate the concrete and steel structural elements as a key part of the architecture. To ensure quality, American Constructors self-performed all of the concrete work on this project. The signature tilt-up element is a 13-inch-thick, 82,300-pound, non-insulated feature panel at the main entry. Other unique tilt-up elements are on the northwest and southwest corners of the building where two pairs of L-shaped panels were created utilizing two different casting techniques. To achieve the highest quality finished product, all of the electrical and special systems’ conduit and box rough-in were installed in the panels prior to pouring. The end result was of such high quality that the architect deleted the interior paint on the tilt-up and left them in an as-cast natural finish. The exterior panels were finished with a combination of light and medium sandblast finishes. These finishes were carried into the exposed interior lobby wall panels, where the light and medium sandblasts were executed in a grid pattern. The LCRA Dalchau Service Center Building D achieved a LEED Silver rating from the USGBC.

Saint Mary Coptic Orthodox Church: 13,750-square-foot spiritual building in Delray Beach, Fla. Submitted by: Houlihan Construction, LLC of Hollywood, Fla. Other TCA member involvement: Johnson Structural Group, Inc., Meadow Burke, HD Supply, White Cap and Nox-Crete Products Group.

EXCELLENCE WINNER | FAN FAVORITE | Saint Mary Coptic Orthodox Church presents an old world theme using the adaptability and strength of tilt-up construction. The structure was originally designed as reinforced masonry with metal gauge framing, lath, and stucco at the facades. The tilt-up conversion features 95 panels plus a full dome, 29 feet 8 inches in diameter and with a weight of 101,900 pounds, cast and lifted as a panel. The front facade contains the project's heaviest panel at 201,220 pounds. This panel rests on four substantial column/panel extensions between the towers, and a series of panels step down behind it to form a vault design. Behind the altar is a series of three panels, at a radius of 11 feet, to form a 180 degree backdrop. Two smaller 3-foot radius panels form a niche for a side chapel. The main dome rests on a solid 8-inch-thick by 6-foot-tall, 360 degree concrete wall that is supported by a 14-inch-thick roof panel, which was all poured on a casting bed and then erected. Two smaller half domes were cast in place on top of radius panels after the panels were erected. The twin towers, which exceed 65 feet in height, were built with a series of panels. One tower serves as an elevator hoist way, while the other is utilized as an exit stairway for the mezzanine. Side slope roof panels serve as a tie between lower outer panels and upper spandrel panels that rest on steel beams with weld connections. Crane access was limited to one elevation. Temporary casting beds were used for the majority of panels with the erection sequence critical in the layout of panels, as the building was constructed front-to-back. Center sections of slab on grade were left out so that the crane crawler could walk through and place panels safely.

Metropolitan Van & Storage: 107,424-square-foot warehouse building in Napa, Calif. Submitted by: Panattoni Construction, Inc. of Sacramento, Calif. Other TCA member involvement: Meadow Burke, and RMW architecture & interiors.

EXCELLENCE WINNER | This high bay warehouse provides temporary storage of personal effects for military personnel during deployment, and it was designed to maximize the floor plate efficiency on a difficult site. The building footprint is a series of three stepped volumes organized to address the curved frontage of the project site, while achieving maximum interior flexibility. One simple decision that enhanced the interior flexibility of the space was to eliminate all recessed entry storefronts, instead opting to place the windows in the plane of the tilted concrete wall panels. With the exception only of the interior steel columns, the entire interior of the building is usable space. The absence of a recessed entry meant that the designers needed to find other means of providing relief and shadow along the exterior facade. For this purpose, a variety of rectilinear forms and layers was added to the building exterior to create a composition rich in visual interest. These design elements use freestanding tilt-up concrete panels in non-traditional ways and explore the use of different finishes and decorative attachments. Most notable are the large wing wall panel extensions at the building steps, finished to resemble cast-in-place concrete. These panels are enhanced with 2-foot edge returns and COR-TEN weathering steel accents. Smaller wing wall panels, also finished to resemble cast-in-place concrete, stand perpendicular to the building face. Other elements include white steel canopies and architectural I-beams, as well as foam banding elements that create large geometric forms on the main building face. The building panels are further enhanced with accent lighting fixtures at each small wing wall and a grid reveal pattern. Together, these elements create a visual dialogue of parts which effectively dispels the mass of the overall building, ensuring that the Metropolitan Van & Storage building achieves a facade that is geometrically modern, sculptural in composition and sympathetic to the human scale.

Galeria 360: 1,045,278-square-foot special project in Distrito Nacional, Santo Domingo, Dominican Republic. Submitted by: Contratistas Civiles y Mecanicos (CCM). Other TCA member involvement: Meadow Burke and Form Services, Inc.

EXCELLENCE WINNER | This commercial gallery involved a complicated architectural design which required a variety of forms in tilt-up panels: curved, semi-curved, and triangular. The project also included a combination of construction systems: tilt-up panels with slab design in two directions (for the elevated slab on the second level), tilt-up panels working as retaining walls with double-T beams (for the parking area), and tilt-up panels with concrete slabs in one and two directions (along the mezzanine). The project’s siting entailed additional considerations. The building footprint takes up almost 90 percent of the total area, so careful scheduling was necessary in the tight space. It is also located adjacent to a large commercial establishment in full operation, which is owned by the same client, and a residential area was in close proximity. Furthermore, contracts between the owner and tenants required that partial deliveries be made to the site and that the site be adapted for customer access. Despite these constraints, by using a fast track system, construction was finished in record time.

Abu Dhabi (UAE) Model Villas: 5,500-square-foot special project in Abu Dhabi, United Arab Emirates. Submitted by: SiteCast Construction Corp. of Ottawa, Ontario, Canada.

EXCELLENCE WINNER | SiteCast Construction completed two traditional "villas" in Abu Dhabi in the spring of 2013. These 5,500-square-foot single-story homes feature traditional UAE architecture, but were constructed using load bearing tilt-up SiteCast concrete panels. The local architecture was reproduced with forming techniques, paying careful attention to panel joint locations and interior wall treatments. An advantage of using tilt-up panels was that the local labor force could be quickly taught the construction techniques on site. Design concepts and skill sets shared with the community included the use of lasers, vibra-screeds, and power trowels; techniques associated with concrete placing, finishing, and  forming; layout process; erecting standards; safety values; and engineering concepts. After completion, the government reviewed the model homes and has requested further homes for its citizens as part of a Government Housing Initiative. Construction of each villa took seven and six weeks respectively, including the landscaping. Traditional homes of this size, type, and style would take a year-plus to construct using the standard masonry technique.

In addition to the top 11 projects, 20 other projects were selected to round out the class of the 23rd Annual Tilt-Up Achievement Awards:

Projects winning in the warehouse distribution facility category include:

• Casas Bahia - Aruja: 1,523,100-square-foot warehouse building in Aruja, Sao Paulo, Brazil. Submitted by: Diase construções LTDA.
• Strathman Sales: 56,950-square-foot warehouse building in Topeka, Kan. Submitted by: Seretta Construction-Atlantic, LLC of Charlotte, N.C. Other TCA member involvement: Meadow-Burke and Whitecap.

Projects winning in the commercial category include:

• Park West 14: 62,537-square-foot commercial building in Morrisville, N.C. Submitted by: Citadel Contractors, Inc. of Apex, N.C. Other TCA member involvement: Meadow Burke, A.H. Harris and Sons, Nox-Crete Products Group and Endicott Clay Products.

Projects winning in the educational category include:

• Cal Baptist University Recreation Center: 40,682-square-foot educational building in Riverside, Calif. Submitted by: Hakanson Construction, Inc. of Brea, Calif.
• CSUSA – Renaissance Charter of Manatee (K-8): 64,146-square-foot educational building in Bradenton, Fla. Submitted by: Woodland Construction Co., Inc. of Jupiter, Fla. Other TCA member involvement: Meadow Burke, HD Supply, White Cap, Nox-Crete Products Group, and LJB, Inc.

Projects winning in the spiritual building category include:

• Carlisle Evangelical Free Church New Building, Phase-I: 19,216-square-foot spiritual building in Carlisle, Pa. Submitted by: SAA Architecture, LLC of Laurel, Md.

Projects winning in the industrial category include:

• Gordon Holdings: 119,397-square-foot industrial building in Englewood, Colo. Submitted by: Intergroup Architects of Littleton, Colo. Other TCA member involvement: Dayton Superior, CMC Construction Services and Nox-Crete Products Group.
• Mitsubishi HVAC Division Headquarters: 558,767-square-foot industrial building in Suwanee, Ga. Submitted by: Martin Concrete Construction Inc. of Kennesaw, Ga. Other TCA member involvement: Architectural Polymers, Inc.

Projects winning in the office category include:

• Annapolis Junction Lot 6: 123,000-square-foot office building in Annapolis Junction, Md. Submitted by: Harvey-Cleary Builders of Gaithersburg, Md. Other TCA member involvement: Powers Brown Architecture.
• Cranberry Crossroads: 90,072-square-foot office building in Cranberry Township, Pa. Submitted by: Al. Neyer, LLC of Cincinnati, Ohio. Additional TCA member involvement: Dayton Superior and Nox-Crete Products Group.
• Discovery Center I: 44,564-square-foot office project in Manassas, Va. Submitted by: Powers Brown Architecture of Houston, Texas.
• Grandview Business Centre: 72,000-square-foot office facility in Surrey, British Columbia, Canada. Submitted by: Double V Construction Ltd. of British Columbia, Canada. Other TCA member involvement: CMC Construction Services and Dayton Superior.
• Grenville Mutual Insurance: 18,000-square-foot office building in Kemptville, Ontario, Canada. Submitted by: Sitecast Construction Corp. of Ottawa, Ontario, Canada. Other TCA member involvement: Dayton Superior, LJB, Inc., Meadow Burke.
• Gyrodata Global Headquarters: 155,000-square-foot office facility in Houston, Texas. Submitted by: E.E. Reed Construction, L.P. of Sugarland, Texas.
• Laguna Springs Corporate Center Phase 3: 220,000-square-foot office building in Elk Grove, Calif. Submitted by: LPAS Architecture + Design of Sacramento, Calif. Other TCA member involvement: Meadow Burke.
• North Fraser Corporate Centre: 124,693-square-foot office building in Burnaby, British Columbia, Canada. Submitted by: Beedie Development Group.
• Providence Medical Office Building: 27,850-square-foot office building in Lacey, Wash. Submitted by: Accrete Construction LLC dba BPCI of Puyallup, Wash.
• Suncor Energy (USA) Inc. Refinery Business Center: 74,668-square-foot office building in Commerce City, Colo. Submitted by: Intergroup Architects of Littleton, Colo.
• Harley-Davidson of North Texas: 50,000-square-foot retail building in Carrollton, Texas. Submitted by: Bob Moore Construction of Arlington, Texas.

Projects winning in the special projects category include:

• Armed Forces Reserve Center: 164,053-square-foot special project in Mustang, Okla. Submitted by: The Korte Company of Highland, Ill. Other TCA member involvement: CMC Construction Services and Miller Builders.

Fan Favorites

In addition to the projects chosen by the panel of judges, TCA gave the public a chance to pick their favorites on Facebook.  The following projects were selected as “Fan Favorites”:

• EagleBurgmann – see description above
• Saint Mary Coptic Orthodox Church – see description above
• Carlisle Evangelical Free Church New Building, Phase 1 – see description above

About TCA and the Achievement Awards

The annual Achievement Awards competition is a year-round opportunity for any TCA member company to participate. Each year, the submittal process closes at the end of June to allow for the evaluation and award process that culminates with public announcement of the recipients during the TCA’s Convention in the fall.  To find out more about this program, the requirements and TCA membership in general, interested persons can visit the awards submission section of the TCA website or contact Jim Baty, TCA Technical Director.

TCA was founded in 1986 to improve the quality and acceptance of site-cast tilt-up construction, a construction method in which concrete wall panels are cast on-site and tilted into place. Tilt-up construction is one of the fastest growing industries, combining the advantages of reasonable cost with low maintenance, durability, speed of construction and minimal capital investment.  For more information about the TCA, visit www.tilt-up.org or contact TCA headquarters at 319-895-6911 or info@tilt-up.org.

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