FAQ

What is ‘tilt up’ construction?

Tilt-up construction involves casting concrete walls horizontally on site using the floor slab or casting beds, and then 'tilting' them upright with a crane before lifting them into their final position.

How does tilt up compare to precast panels?

Precast panels are fabricated off-site and then transported to the construction site. Tilt up panels are formed on site using the floor slab.

The most suitable method for your project will vary depending on the specifics of your site, space and design plans.

Some main differences are:

1. Cost: Generally speaking, tilt up is a more cost effective option when compared to precast. This is due to precast incurring additional costs of transportation and factory overheads.

2. Design: Tilt Up panels are cast on site allowing more flexibility in design - usually being much larger and offering the ability to create unique panel shapes. Precast panels on the other hand are restricted to approximately 4 metres in width to be suitable for delivery on roads.

3. Space: Precast is the preferred method when there is insufficient space on site to cast the concrete panels horizontally on the slab. This is sometimes the case in high density urban areas where there space and access is limited.

4. Time: Due to being able to utilise the floor slab as a casting bed, more tilt up panels can be manufactured at once thus speeding up the project completion time. With enough space, over 40 panels can be poured per week, which can each be up to twice the size of a standard precast panel.

Is there a difference in the final product?

The main difference is that precast panels will be narrower (generally 4 metres wide) due to limitations of transporting them on trucks from the place of fabrication to the site. Other than this, the end result is visually much the same.

What is involved in the tilt up panel process?

Step 1: Drawings

Request a ‘Panel book’ and ‘Panel Layout’ from a ‘Tilt Up Draftsman’.

We will review the design of the panels to discuss options that may improve the quality and speed of the build.
The Panel book takes at least two weeks for small to medium sized projects and longer for multi-unit complexes.

2. Request a ‘Casting Layout’ from the Crane Contractor.

Shows the cranes set up locations and the location of the panels in their horizontal stacked positions on the slab.
Generally takes less than a week for most small - medium sized jobs.

Note: Work on larger projects sometimes begins on buildings or sections that have tilt up drawings already completed to ensure no time is wasted.

Step 2: Pour Finished Floor Slab

The finished floor slab will be used to cast the wall panels horizontally on the floor.

A compound called Bond Breaker is sprayed onto the slab to stop the panels bonding to it.

If more room is required, Casting Beds (70mm thick bed of concrete) can be poured close by to create more space to cast panels on.

Step 3: Build Panels On Site

We'll then form the panels all accross the slab. Once the first layer of panels are is poured, we will spray bond breaker on them to be able to build more panels on top (stack casting) which maximises space.

Generally, a 3-4 day turnaround is enough to Form, Steel and Pour each layer of panels.

The number of layers is determined by the crane contractor when forming the casting layout. Generally speaking - the more floor space you have - the less pours there will be. There are usually 5 pours or less on a average sized job. Larger multilevel complexes can have over 50 pours.

About 10-15 Panels are typically poured in each of the first few layers, with pours becoming smaller as you get to the 4th and 5th layers.

Once all panels are poured, allow one week to cure before lifting (assuming 40mpa concrete is used on the last pour).

Step 4: Erect Panels with Crane

20 - 30 panels are typically erected in a single 10 hour day.

The panels will be held up by braces until the structural steel is installed.

Step 5: Install Structural Steel:

Your Structural Steel Contractor will supply and install the plates, brackets, beams and rest of the structural steel that ties all the panels together at the roof.

Install on small/medium sized projects typically takes 1-4 weeks depending on the size of the job and experience of your structural steel installers.

Step 6: Finishes

Panel joints are sealed with caulk (UV Resistant and Fire Rated)

Grout beneath panels and Patch exposed lifting points.

Your Roofing Contractor and Painters would now come in to finish off.

Contractors Involved:

Tilt Up Panel Draftsman/Engineer

- Provides a ‘Panel Book’ which shows the dimensions of panels and locations of various components such as ferrules for structural steel connections, lifting points, brace points, dowel sleeve locations, false joints, recesses, doors and more.

- Provides a ‘Panel Layout’ showing the final location of each panel, its orientation and bracing direction.

Tilt Up Panel Builders

- Guides you through the overall process and coordinates other contractors and suppliers involved to ensure the whole process is easy and efficient.

- Provides the Form/Reo/Pour services specialised for Tilt-Up Panels.

- Provide Panel Erection Services.

- Note: The other contractors and suppliers listed below are sometimes packaged into the Tilt Up Panel Builders’ Scope of works. This raises costs and is more common for clients with larger budgets that want to take on less risk and/or want to deal with a single contractor only.

Crane Contractor

- Provides the Mobile Crane to Erect Panels

- Provides a ‘Casting Layout’ which shows the Tilt Up Panel Builder where to build the panels, which considers the reach of the crane, the various set up locations around the site/slab and the specific sequence they need to be lifted in.

Joint Sealer and Patcher

- Seals panel joints with Caulk

- Grouts beneath panels with non-shrink grout.

- Patches lifting locations and brace points by filling them up to blend in with the panel, or attaching lifting caps to cover them up.

- Note: Joint sealing, grouting and patching happen after the structural steel has been installed and the braces have been removed. If done beforehand, the winding in and out of props whilst installing steel will compromise the integrity of the grout and caulk.

Suppliers Involved:

Concrete and Steel Suppliers

- Supplies all Concrete, mesh, bars, stirrups, chairs and dowels required.

Panel Hardware Supplier

- Supplies all hardware that gets cast-in to the panel such as Lifting Points, Ferrules for structural steel ferrule connections, Bond Breaker, architectural grooves, Braces and more

Door Jamb Supplier

- Supplies cast-in Door Frames that get embedded into the concrete.

- Note: All the above is Installed by the Tilt Up Panel Builders

What are the benefits of using tilt up panels?

Cost-Effective: Tilt-up construction is known for its cost-effectiveness. It can provide savings in materials, labor, and construction time compared to traditional construction methods. The efficiency of casting and lifting large concrete panels on-site helps reduce overall construction costs.
Speed of Construction: Tilt-up construction is relatively fast compared to other methods. Once the concrete panels are cast and cured, they can be lifted and tilted into place quickly. This accelerated construction process can result in shorter project durations, allowing for faster occupancy or reduced construction loan costs.
Design Flexibility: Tilt-up construction allows for flexibility in design. Concrete panels can be customised to meet specific architectural requirements, including various shapes, sizes, textures, and finishes. This flexibility opens up possibilities for unique and visually appealing building designs.
Durability and Strength: Tilt-up concrete panels are known for their durability and strength. Concrete is a robust material that provides resistance against fire, weathering, and impacts. Tilt-up buildings are near impenetrable and are known for their long lifespan and low maintenance requirements.
Energy Efficiency: Tilt-up construction can contribute to energy-efficient building design. The thermal mass of concrete panels helps regulate temperature fluctuations, reducing heating and cooling loads. Additionally, the flexibility of insulation placement within the wall assembly can enhance energy efficiency.
Fire Resistance: Concrete is inherently fire-resistant, making tilt-up construction a preferred choice in areas where fire safety is a concern. Tilt-up buildings offer added protection against fire spread, contributing to the safety of occupants and neighbouring properties.
Versatility and Adaptability: Tilt-up construction is versatile and can be employed for a wide range of building types, including industrial, commercial, educational, and residential structures. It can accommodate various architectural styles and building requirements, offering adaptability to different project needs.

What are some common uses for the tilt up construction method?

Data Centres: Tilt-up construction is increasingly utilised in the construction of data centres. The method allows for the quick and efficient construction of secure and reliable facilities to house servers and IT infrastructure.
Automotive Dealerships: Tilt-up construction is well-suited for automotive dealerships and showrooms. The large, open spaces provided by tilt-up panels allow for the display of vehicles and the flexibility to accommodate different layouts and configurations.
Cold Storage Facilities: Tilt-up construction is commonly employed in the construction of cold storage warehouses and facilities. The durability and insulating properties of tilt-up concrete panels make them an excellent choice for maintaining controlled temperatures required for storing perishable goods.
Healthcare Facilities: Tilt-up construction can be used for various healthcare facilities, including hospitals, clinics, and medical office buildings. It allows for the quick construction of robust structures while accommodating the specific layout requirements of healthcare spaces.
Residential Buildings: Tilt-up construction is increasingly being utilised in the construction of multifamily residential buildings such as apartments and townhouses. It offers cost-effectiveness, speed of construction, and flexibility in accommodating different unit layouts.
Hotels and Hospitality: Tilt-up construction can be employed in the development of hotels and hospitality facilities. It offers the advantages of efficient construction, adaptability to different hotel layouts, and cost-effectiveness.
Self-Storage Facilities: Tilt-up construction is commonly used in the development of self-storage facilities. The method allows for the quick construction of durable and secure storage units with flexible layout options.
Industrial Warehouses and Distribution Centres: Tilt-up construction is commonly employed in the construction of industrial warehouses and distribution centres. The speed and cost-effectiveness of tilt-up construction make it ideal for large, open-span buildings that require efficient use of space for storage and logistics.
Retail Shopping Centres: Tilt-up construction is often utilised in the development of retail shopping centres. The method allows for the rapid construction of large, open retail spaces, providing developers with a cost-effective solution for accommodating multiple stores and maximising rental space.
Office Buildings and Corporate Centres: This approach allows for the quick erection of office spaces, providing flexibility in accommodating various layouts and customisations based on tenant requirements.
Educational Facilities: Tilt-up construction is used in the development of educational facilities such as schools and universities. The method allows for the construction of durable and functional buildings within a shorter time frame, which is beneficial for educational institutions that often have strict deadlines and budget constraints.
Recreation and Sports Facilities: Tilt-up construction is well-suited for the development of recreation centres, sports facilities, and community centres. It offers flexibility in creating large, open spaces for sports activities, gymnasiums, and multipurpose rooms.
High End Residential: Tilt-up panels are increasingly being used for high end bespoke luxury homes. The design capabilities are limitless, allowing users to create magnificent structures on a grand scale. Apart from looking incredible, tilt up concrete panels have the added benefit of being fire proof, an excellent insulator and hurricane proof.

Why should I use Sydney Tilt Up for my project?

Sydney Tilt Up are a third generation, family owned business operating across NSW and surrounds for over 30 years. As one of the oldest tilt up panel builders in Australia, we are highly experienced and have a long track record of providing high quality results for our clients.

Sydney Tilt Up are at the forefront of tilt panel innovation, employing secrets of the trade and the latest technology to optimise efficiency and reduce costs.

We will work with you every step of the way to make the building process as smooth as possible. Our aim is to ensure your project is completed to the highest standard, on time and within budget. Sydney Tilt Up hold all relevant building licenses, certifications and insurances so you can rest assured you are in safe hands.

What are some well known buildings that utilise concrete tilt up panels?

Tesla Gigafactory, Nevada, USA: The Tesla Gigafactory in Nevada is one of the largest buildings in the world, and is designed with tilt-up concrete panels in its construction.
Amazon Fulfilment Centres: Numerous Amazon fulfilment centres across the globe have been constructed using tilt-up concrete panels. These large-scale warehouses utilise the efficiency and cost-effectiveness of tilt-up construction.
IKEA Stores: IKEA, the Swedish furniture retailer, has utilised tilt-up concrete panels in the construction of many of its stores worldwide. These stores are known for their large size and distinctive blue and yellow exterior.
Walmart Super centres: Walmart, the multinational retail corporation, has incorporated tilt-up concrete panels in the construction of its Super centres. These large retail stores often span several hundred thousand square feet.
Bunnings Warehouse: Bunnings, the popular home improvement retailer, has constructed many of its warehouse stores using tilt-up concrete panels. These buildings are known for their large size and simple design.
Masters Home Improvement: Masters Home Improvement, another retail chain in the home improvement sector, has utilised tilt-up construction for many of its stores in NSW. These stores feature a mix of tilt-up concrete panels and other construction elements.
ALDI Distribution Center, Prestons: ALDI, the discount supermarket chain, has a large distribution centre in Prestons, NSW, constructed using tilt-up concrete panels. This facility serves as a hub for their supply chain operations.
Harvey Norman Warehouse, Auburn: The Harvey Norman Warehouse in Auburn, NSW, is a prominent example of a tilt-up concrete panel building. This large retail warehouse showcases the versatility of tilt-up construction in commercial applications.
Beyonce and Jay Z’s Californian home: This newly built mansion is the most expensive property ever sold in California at a whopping $200 million USD. The grand residence is an architectural delight and is constructed from tilt up concrete panels.
Daikin Texas Technology Park: This is the largest tilt panel structure in the world, measuring 1,280,160 square metres. The structure is used as a manufacturing and distribution campus for Daikin.

What are the environmental impacts of tilt up concrete panels?

Concrete is a sustainable construction material that is increasingly being used as the green building movement grows. Concrete offers durability, low maintenance, local availability, high strength and no impact on indoor air quality; meaning concrete can be used on every type of end-use facility.

During renovation, remodelling, or demolition, tilt up wall panels can be recycled by crushing the concrete which can be used as the sub base for sidewalks, parking lots, casting slabs, or roads. Similarly, recycling occurs with the temporary slab used to cast the panels.

Sydney Tilt Up choose to use sustainable materials where possible. Our clients can opt for sustainable concrete mix designs that use recycled materials such as fly ash, slag, or recycled aggregates. These materials reduce the demand for virgin resources and minimise the environmental impact of concrete production.

Our construction materials are generally locally sourced to reduce transportation distances and associated carbon emissions. As well as supporting the local economy, this also reduces the environmental impact of long-distance transportation.

We adopt sustainable construction practices, such as efficient waste management, recycling of construction waste, and minimising site disturbance during construction.

GET IN TOUCH