Construction procedures

for tilt-up buildings

Editor’s note:
Readers with specific questions on
tilt-up construction are referred to the
PROBLEM CLINIC section of this is-
sue where detailed question and an-
swer material if presented.
ood planning is an impor-
The floor slab must be level and
smoothly troweled. If the floor con-
tains openings for pipes or other
utilities, a 3⁄4-inch skin coat over sand
fill can be used to close up the open-
ings temporarily. Smoothness is im-
portant in preventing mechanical
bond and is necessary for clean
tively simple examples of form
work, should be securely bolted or
weighted down to the casting sur-
face. Top and bottom edge form
sections need to be braced and
squared. If side forms contain holes
for rebars, these forms usually are
split 2 by 6’s to facilitate stripping.

G tant part of all successful

construction work, but it is
especially critical in tilt-up
construction if the many inherent
economics of this technique are to
be realized. A carefully worked out
schedule of operations is essential
to ensure that the proper sequence
of panels is ready for the tilt-up
process. A casting layout should be
drawn prior to construction to de-
termine proper use of space and ac-
cess for material and equipment.
Where crane capacity is marginal,
extra safety can often be achieved
by improving crane access and
t h e re by shortening the boom
length.
The panels should be cast as close
to their final position as possible.
Recommended practices for quality
concrete should be followed to en-
sure that panels attain a minimum
strength of 3,000 psi within 28 days.
A helpful device for preplanning a
large tilt-up building is the critical
path method of scheduling. Provi-
sion for an efficient casting layout
can be coordinated with the activi-
ty-time schedule.
cleavage when lifting. A properly
constructed floor slab should have a
thoroughly compacted subgrade
with adequate strength and thick-
ness to carry material trucks and the
heavy mobile cranes that may be
needed in the tilting process. Floor
jointing should be located between
panels whenever possible.
Curing of the concrete floor slab
is important to obtain a uniform
surface and prevent dusting and
plastic shrinkage cracks. A good
bond-breaking agent is also essen-
tial in tilt-up construction to obtain
a clean, trouble-free lift from the
floor slab. Because curing and bond
breaking are critical to successful
tilt-up work, materials and tech-
niques are discussed in detail later
in this report.
Edge forms
One of the obvious advantages of
tilt-up wall construction is the sav-
ings in form material and labor.
Panel edge forms, which are rela-
figure 9
(See Figure 9)
Window and door openings in
panels are rarely a problem to form.
The easiest way to include windows
in a tilt-up panel is to cast directly
against the steel sash. A wood-form
buck should be sanded and primed
to prevent swelling, or allowance for
swelling can be made with diagonal
cuts through the bucks. All opening
forms should be held down on the
casting platform with weights. Ex-
posed surfaces of sash and wood
surrounds should be given a coat of
bond-breaking compound.
Reinforcement
The usual building code require-
ment for wall reinforcement calls
for a steel area 0.0015 to 0.0025
times the area of the concrete in
cross-section. Number 4 deformed
bars 16 inches on center for a 6-inch
panel are common. Around open-
Charts and diagrams on insert place-
ment, rigging and bracing were pro-
vided by the Engineering Department
of Burke Concrete Accessories, Inc.

Casting surface
The concrete floor slab of the
building is usually the most conve-
nient place for casting tilt-up pan-
els. Other casting platforms or cast-
ing beds may be necessary when
panels are prepared outside of the
building. The following are impor-
tant considerations in the construc-
tion of an industrial floor to be used
as a casting platform.

The supporting feet of the lifting and bracing in-
serts must rest on top of the rock to insure
proper imbedment and prevent rust. The insert
supplied should be for a slab thickness of the
dimension “C.” The insert should be securely
wired to the reinforcing steel to prevent move-
ment when the insert feet are placed on the un-
even aggregate. The standard 1⁄4 -inch to 1⁄2-inch
clearance below the top surface of the slab
should be maintained, and the usual slotted lag
stud used for setting.
When an exposed aggregate panel is cast face
up a lifting bolt should be used for setting in-
stead of the slotted lag stud. Since the top sur-
face need not be troweled the bolt can protrude
well above the surface of the exposed archi-
tectural aggregate. The threaded portion of the
bolt should protrude 1⁄2 inch to 1 inch below the
coil. The insert supplied should be for a slab
thickness of the dimension “C.”
figure 10
proper bolt, insert size and placement
ings, number 5 bars are added to
strengthen the corners and edges.
When wire fabric is the principal re-
inforcement, dowel bars are provid-
ed where panels and columns are
tied together.
Mats of reinforcement assembled
on a jig are lowered onto stainless
steel, galvanized or plastic-coated
chairs to hold them near the center
of the panels. Except for unusual
conditions the center position pro-
vides the greatest strength for the
panel.
When lifting with exposed aggregate up it is im-
portant to obtain a firm even bearing for the lift
plate. One manner this may be done is as fol-
lows: 1. Place the proper length lifting bolt
through a 5⁄8-inch plywood doughnut and the lift
plate and start it into the insert. 2. Raise the ply-
wood and shovel pea gravel onto the exposed
rock to fill the voids. 3. As the bolt is tightened,
rotate the plywood to screed off the pea gravel
until the plywood is firmly against the highest
rocks.
The insert supplied should be for a slab thick-
ness of the dimension “A.” The insert should
then be 1⁄4 inch to 1⁄2 inch below the surface. The
proper length lifting bolt will have the threaded
portion of the bolt protruding 1⁄2 inch to 1 inch
below the coil. Make sure the lift plate is cor-
rectly oriented and bearing firmly on the con-
crete before lifting. The bolts should be firmly
tightened. D=2-3⁄4 inches for single swivel lift
plate. D=3/4 inch for double angle lift plate.
Concrete placement and curing
The concrete is placed the same
way as in a floor slab. Care must be
taken to prevent rock pockets along
the bottom of the edge forms and to
p re vent damage to the bond-break-
ing material. Screeding, compacting
and floating are also the same as for
floors. Techniques for finishing de-
pend on the texture desired.
Curing is started as soon after fin-
ishing as possible without surface
marring. If the panel is to be left ex-
posed, a curing compound should
be used that will not stain or discol-
or the surface. If the panel is to be
painted, care must be taken to select
a bond breaker that does not trans-
fer to the concrete surface.
Lift and brace inserts
The size and placement of lifting
inserts will depend on the size and
shape of the panel, the surface de-
sign and the casting method (face
up or face down). Figure 10 illus-
trates the proper insert placement
for various situations.
Lift and brace inserts must be
carefully positioned in the slab at
proper distances from edges and
openings and must be kept upright
during the casting operation. A
guide to the correct number and po-
sition of inserts is given in Figure 11.
Setting bolts should be the correct
length and not so long as to leave a
void in the slab beneath the insert
after removal. Plastic-capped in-
serts are now available which sim-
plify this procedure.
Rigging for the lift
Cables for lifting slings need to be
long enough to provide at least a
60-degree angle from the plane of
the panel, and the rigging design
should provide approximately
equal stress on all inserts. Three-
point lifts are not recommended ex-
cept when a modified M or other
automatic equalizing system is be-
ing used. A turnbuckle is not usual-
ly adequate to balance stresses. Var-
ious rigging arrangements are
illustrated in Figure 12. In general
the location of pick-up points and
the design of strongbacks should be
carried out under supervision of a
licensed engineer.
Tilting procedures
The method of erection will de-
pend largely upon two factors:
1. Whether the crane can operate on
the floor slab or must stay outside
the perimeter of the building;
2. Whether the panel is to be cast
face up or face down.
 O rd i n a rily a crane on the floor
slab is preferable, especially where a
smooth roadway is required for
walking the panel into position. The
suicide pick, where the crane opera-
tor is under the panel during lifting
and the attach points on the panel
are hidden from view, should be
avoided.
Casting and erection layouts
should be carefully prepared with
thought given to crane size, clear-
ances for the lifting sequence, and
placing of the concrete from the
transit mixer. Because of edge re-
bars, setting a panel between two
sections that have already been
erected should be avoided if possi-
ble. Braces may be attached to the
panels before lifting.
Exterior surface treatments, such
as a pebble finish, should be cast
with the outside face up. This gives
the contractor better control of the
treatment and enables him to clean
and seal the surface before erection.
This involves filling the pick-up and
bracing insert holes from the ve rt i-
cal position.
Vacuum lifters have been used in Alternative crane positions formed beside each other in rows to
some areas instead of pick-up in- permit a substantial amount of cast-
When the wall panels are to be
serts. Vacuum equipment is particu- erected before construction of the ing at one time.
larly efficient for picking up irregu- building frame, the crane can oper- In the tilting process an eight
lar shaped panels and those having ate easily on the floor slab. Gi ve n wheel truck crane operating on the
door and window openings. this approach, wall panels can be floor slab uses a horizontal lifting
bar with cables threaded over pul-
knee brace and cross lacing details leys to produce two eight-hook
points as needed. The arrangement
equalizes the lifting force on all
points simultaneously and allows
the slab to tilt to a vertical position
as it is suspended in the air. It is then
placed on the foundation and tem-
p o ra rily braced. This method pro-
vides good visual control.
If the structural frame is erected
first, the crane must operate outside
the building; this usually re q u i re s
that wall panels be cast on the floor
slab adjacent to their final positions
in the wall. When the panel is tilted
and rotated into place the underside
becomes the inside face of the wall.
Wall panels are tilted and positioned
Knee brace must have positive connection at each end and connect at mid-span with an adjustable strongback that
of brace. Cross lacing must be continuous and have positive connection at each is mounted on the panel’s upper
brace and at the end of each line. face and hooked to a crane. The
 Maximum control
and safety is
possible when the
crane is able to
operate on the floor
slab within the
building, tilting the
panel in the manner
shown here.

With the roof already in place, the crane must operate

from outside the building. Strongbacks are used on
the panel which is raised, turned 180 degrees and
bolted to the roof structure.

strongback carries two removable

These rock-faced panels
were cast face down.
With the crane operating
outside the building, the
result is that the operator
cannot observe the
bracing crew or
attachment points. If the
panel fell it would fall
toward the crane.
jacks with wheels located beyond
the lower edge of the panel allowing
the panel to roll outward as it is lift-
ed. Once the panel clears the roof,
the jack wheels are removed and the
panel is lifted and turned 180 de-
grees; then it is attached to the roof
or frame. In this method the crane
operates completely outside the
building.
At times the crane must operate
outside the building even before the
frame is erected. Under this circum-
stance panels may be cast on the
floor slab or on a waste slab, wood
platform or even hard-packed earth.
Panels may also be cast in a stack in
the reverse order of their use. Cast-
ing panels face down permits place-
ment of pick-up points and bracing
an example of the use of the above chart left of 27’ in the “H” column. The 27’ line intersects the
curve at 3’ and 12’, indicating a safe bracing of 3’ of pan-
el width or 12’ of panel width if cross lacing and knee
The brace points required for a panel 27 feet above finished bracing are used.
floor are found as follows:
1. Enter the “H” column of the table at 27’. Summary
2. Read to the right to “0.667H” column for the distance up H=27’
the panel of 17’-4”.
0.667H=17’-4”
3. Read further right to “0.385H” column for the distance
out on the floor of 10’-0”. 0.385H=10’-0”
4. Read to the extreme right to “0.770H” column for the ap- 0.770H=20’-0”
proximate brace length of 20’-0”. 3’ of panel width per brace
5. To determine the number of braces required read to the 12’ with cross lace & knee brace
inserts on the back side, but this
leaves the crane operator out of vi-
sual contact with the bracing crew.
Bracing the panels
After tilt up, the panels must of
course be temporarily braced until
the joints are secure, columns are
cast, and other steps taken to estab-
lish the structural integrity of the
building. Wind loads on exposed
vertical panels can be severe. A wind
velocity of 50 to 60 miles per hour
produces a horizontal force of ap-
proximately 10 pounds per square
foot. The addition of a driving rain
can increase the pressure to about
12 pounds per square foot.
Adjustable tilt-up braces that are
knee-braced and cross-laced are
recommended in most instances.
The braces should be positively an-
chored to imbedded inserts of suffi-
cient strength to resist both hori-
zontal and vertical forces. The angle
between brace and floor should be
between 45 degrees and 60 degrees,
and all connecting bolts must be
checked to ensure tightness and
prevent flutter of the braces.
PUBLICATION#C710428
Copyright © 1971, The Aberdeen Group
All rights reserved