• Worldwide applications of tilt‐up concrete construction • Advancements in tilt‐up concrete construction & building market diversity • Overview of tilt‐up concrete construction benefits • Tilt‐Up Villa case study

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Tilt-Up Concrete Construction
Advancements & ApplicationsPresented by
Mr. Fadi Elayache
Special Consultant to CON/STEEL Tilt-Up Systems, MENA Region
www.ljbinc.com
www.ljbinc.com
Today’s Speaker
• Mr. Fadi Elayache (Program Manager at Samsung C&T)
– Special Consultant to CON/STEEL Tilt‐Up Systems, MENA
Region
– 20+ years of experience in the construction industry
– International experience in the US, Lebanon & UAE
– Past instructor at University of Sharjah, Notre Dame
University ‐ Louaize, and Cleveland State University
– Signature projects include Universal Studio Dubailand ,
Palm Jumeirah Villas and recently Dubai Park

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www.ljbinc.com
Today’s Agenda
• Worldwide applications of tilt‐up concrete
construction
• Advancements in tilt‐up concrete construction &
building market diversity
• Overview of tilt‐up concrete construction benefits
• Tilt‐Up Villa case study
www.ljbinc.com
Learning Objectives
• Understand the various building markets that benefit from
tilt‐up concrete construction
• Learn how the construction schedule for tilt‐up compares
to conventional construction
• Learn tools for managing the quality of tilt‐up construction
activities
• Identify when tilt‐up concrete construction is the preferred
solution for a new facility design and construction

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What is Tilt‐Up?
• Formed and cast horizontally on‐site
• Reinforced concrete wall panels
• Tilted into final vertical location
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What is Tilt‐Up?
• Architectural façade in addition to structural member
• Load bearing perimeter for vertical loads
• Shear wall perimeter for lateral loads

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Tilt‐Up Worldwide
• United States
– 15% of all industrial buildings are built with tilt‐up
– Companies such as Amazon, FedEx and Procter & Gamble
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Tilt‐Up Worldwide
• United States continued
– Office, Educational, Retail

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Tilt‐Up Worldwide
• United States continued
– Data centers, Recreational and Housing
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Tilt‐Up Worldwide
• Canada
– Cold weather climates & high seismic regions

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Tilt‐Up Worldwide
• Central America
– Mexico, Dominican Republic, Panama, Grand Cayman, …
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Tilt‐Up Worldwide
• South America
– Brazil, Argentina, Colombia, …

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Tilt‐Up Worldwide
• New Zealand
– Extremely high seismic loads
– Liquefiable soils
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Tilt‐Up Worldwide
• South Africa
– Sibaya Casino

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Tilt‐Up Worldwide
• Middle East
– Residential projects in Jordan and UAE
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Advancements in Tilt‐Up
• The growth in tilt‐up construction has been fueled by
its ability to …
– Adapt to a wide variety of building end uses
– Provide architects with design freedom beyond
conventional construction methods

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Advancements in Tilt‐Up
• Panel heights & widths
– 90‐feet and taller
– 80‐feet and wider
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Advancements in Tilt‐Up
• Curved panels

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Advancements in Tilt‐Up
• More curved panels
– Casting beds of lumber or earth forming
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Advancements in Tilt‐Up
• Expansive areas of glass
– Curtain wall with tilt, or …
– Continuous ribbon glass achieved with deep recess in panel

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Advancements in Tilt‐Up
• Economical at any building size
– As large as 1.7M square feet (170,000 sq. m.)
– As small as 1,500 square feet (150 sq. m.)
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Advancements in Tilt‐Up
• Complete site‐cast structures (walls, floors, ceilings)
– Constructed in 6 to 7 weeks vs 52 weeks with traditional
masonry

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Advancements in Tilt‐Up
• Combined with cast‐in‐place superstructure
– Cast‐in place concrete interior columns and floors
– Single‐story panels stacked 4‐stories & 5‐stories high
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Advancements in Tilt‐Up
• Six‐stories with steel‐framed interior core
– Vertical stacking of panels between 4th and 5th stories

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Advancements in Tilt‐Up
• Seven‐stories with CIP concrete interior core
– Vertical stacking of panels between 2nd and 3rd stories, and
between 5th and 6th stories
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Advancements in Tilt‐Up
• Eight‐stories with CIP concrete interior core
– 16” panel covering all 8 stories as one panel !!!
– Vertical stacking of 8” panels between 4th and 5th stories

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Advancements in Tilt‐Up
• Blast resistance
• Prevention of Progressive Collapse
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Advancements in Tilt‐Up
• According to the US Department of Energy, …
– The most cost‐effective energy efficiency comes from a
well‐insulated building
• ASHRAE 90.1‐2007 & International Energy
Conservation Code 2009
– Latest coded require continuous insulation in building
envelopes

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Advancements in Tilt‐Up
• Insulated tilt‐up sandwich panel
– Continuous envelope with ZERO thermal breaks
– Concrete layers connected by fiber composite connectors
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Advancements in Tilt‐Up
• Thermal mass of insulated tilt‐up
– Mass of concrete interior to insulation stores heating & cooling loads
– Saves energy costs by reducing peak loads

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Advancements in Tilt‐Up
• Thermal mass of insulated tilt‐up
– R‐10 material but R‐24 performance
– The dark colors in the thermal photograph indicate areas where the
internal heat is retained in the building
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Advancements in Tilt‐Up
• Non‐building structures
– Bridges and walkways

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Advancements in Tilt‐Up
• Non‐building structures
– Parking garages and monuments
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Benefits of Tilt‐Up
• For contractors
– Cost savings from reduced labor and economy of
materials
– Schedule savings by reducing labor and
dependence on pre‐fabricated items

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Benefits of Tilt‐Up
• For owners
– Savings on first costs (i.e. cost of construction)
– Earlier occupancy / earlier return on investment
– Long term maintenance savings
– Long term energy savings
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Benefits of Tilt‐Up vs Masonry
Tilt-Up Masonry Comparison
Joints only between panels
Horizontal & vertical joints
@ every unit
Maintenance advantage –
tilt-up
Concrete surface of panel is
exterior surface
Requires stucco coating
over exterior surface
Cost advantage – tilt-up
Constructed on the ground Built from scaffolding
Speed, cost & safety
advantage – tilt-up
Easy to form openings,
including arches
Openings and arches require
lintels and forming
Speed, cost and quality
advantage – tilt-up
Less labor, shorter schedule More labor, longer schedules Cost advantage – tilt-up

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Tilt-Up Precast Comparison
Heights up to 90-ft tall Limited to 50-ft tall Design advantage – tilt-up
Widths up to and exceeding
50-ft
Limited to 12-ft to 14-ft
wide
Design & Speed advantage –
tilt-up
Fewer panel joints More panel joints
Speed & Cost advantage –
tilt-up
Formed, cast and erected in 8
to 12 weeks (for 10,000 SQ. M
building)
Lead times of 12 to 16 weeks Speed advantage – tilt-up
Quality observed &
controlled on-site
Quality controlled at plant; not
observed by owner or builder
Quality advantage – tilt-up
Benefits of Tilt‐Up vs Precast
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Tilt‐Up Villa Case Study
3500mm
3500mm
1000mm
8000mm
8000mm
2600mm
2000mm
1200mm
600 x 600 mm Recessed Plaster
• Two‐story facade
Surface Area Analysis of Building
Façade
Description
Area
(Sqm)
% of
total
Openings 15.2 24%
Concrete
Columns/lintels
18.32 29%
Concrete Parapet 8 13%
Maonary blocks 22.48 35%
Façade Area = 64 100%
Surface Area Analysis of Building
Façade
Description
Area
(Sqm)
% of
total
Openings 15.2 24%
Concrete
Columns/lintels
18.32 29%
Concrete Parapet 8 13%
Maonary blocks 22.48 35%
Façade Area = 64 100%

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Traditional CIP + AAC + Plaster
200 mm AAC
Block Wall with
Non insulated
150 mm parapet
wall
3500mm
3500mm
1000mm
8000mm
8000mm
Roof
1st Floor
Ground Floor
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Traditional Construction Wall Panel 200 mm AAC
Block + Concrete Columns+ Plaster
SN Description Unit Qunatity
Unit cost
(AED)
Total (AED)
1 concrete columns cum 2.1 1200 2520
2 Concrete slab edge cum 1.28 750 960
3 Window lintel cum 0.192 1000 192
4 door arched lintel cum 0.512 1500 768
5 RC Parapete cum 1.2 1000 1200
6
Block supply AAC 200 mm thick incl
wastage sqm 22.48 65 1461.2
7
Block Installation including mortar
& accessories sqm 22.48 35 786.8
8 External Plaster sqm 56.8 50 2840
9 Internal Plaster sqm 34.4 40 1376
10 Opening surrounds plaster lm 36.4 15 546
11 Decorative plaster each 12 50 600
Total 13,250
Ave Cost Per Sq meter of
Façade = 207
Traditional Construction Wall Panel 200 mm AAC
Block + Concrete Columns+ Plaster
SN Description Unit Qunatity
Unit cost
(AED)
Total (AED)
1 concrete columns cum 2.1 1200 2520
2 Concrete slab edge cum 1.28 750 960
3 Window lintel cum 0.192 1000 192
4 door arched lintel cum 0.512 1500 768
5 RC Parapete cum 1.2 1000 1200
6
Block supply AAC 200 mm thick incl
wastage sqm 22.48 65 1461.2
7
Block Installation including mortar
& accessories sqm 22.48 35 786.8
8 External Plaster sqm 56.8 50 2840
9 Internal Plaster sqm 34.4 40 1376
10 Opening surrounds plaster lm 36.4 15 546
11 Decorative plaster each 12 50 600
Total 13,250
Ave Cost Per Sq meter of
Façade = 207

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Pre‐Cast Sandwich Concrete Wall Panel
150 mm + 50 mm Insulation + 100 mm
SN Description Unit Quantity
Unit
cost
(AED)
Total
(AED)
1 250 mm Insulated Walls cum 12.2 1250 15250
2 Non Insulated Parapet cum 1.2 1000 1200
3 Total = 16,450
4
Ave Cost Per Sq meter
of Façade = 257
Pre‐Cast Sandwich Concrete Wall Panel
150 mm + 50 mm Insulation + 100 mm
SN Description Unit Quantity
Unit
cost
(AED)
Total
(AED)
1 250 mm Insulated Walls cum 12.2 1250 15250
2 Non Insulated Parapet cum 1.2 1000 1200
3 Total = 16,450
4
Ave Cost Per Sq meter
of Façade = 257
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Tilt‐Up Alternative
3500mm
3500mm
1000mm
8000mm
8000mm
2600mm
2000mm
1200 mm
600 x 600 mm
Recessed Plaster
Roof
1st Floor
Ground Floor
Sandwich Wall
with 50 mm
insulation
Non insulated
150 mm parapet
wall

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Tilt‐up Wall Panel 150 mm thick with Furring channel +
50 mm Insulation + 12 mm GWB
SN Description Unit Qunatity
Unit cost
(AED)
Total (AED)
1
concrete wall 15 cm thick including
Formworks Reinf, & Miscel cum 7.32 650 4758
2 Concrete slab edge cum 0.64 550 352
3 lifting inserts each 8 50 400
4 Crane hire hr 1 200 200
5 Bracing hire 3no. week 6 75 450
6 Bracing inserts each 8 50 400
7 Bond Breaker Sqm 61.296 5 306.48
8 Panel Base Grouting lm 8 20 160
9 Surface preparation sqm 56.8 15 852
10 Opening surrounds plaster lm 36.4 15 546
11
furring chanels, 50 mm insulation +
12mm GWB sqm 34.4 50 1720
Total 10,144
Ave Cost Per Sq meter of Façade = 159
Tilt‐up Wall Panel 150 mm thick with Furring channel +
50 mm Insulation + 12 mm GWB
SN Description Unit Qunatity
Unit cost
(AED)
Total (AED)
1
concrete wall 15 cm thick including
Formworks Reinf, & Miscel cum 7.32 650 4758
2 Concrete slab edge cum 0.64 550 352
3 lifting inserts each 8 50 400
4 Crane hire hr 1 200 200
5 Bracing hire 3no. week 6 75 450
6 Bracing inserts each 8 50 400
7 Bond Breaker Sqm 61.296 5 306.48
8 Panel Base Grouting lm 8 20 160
9 Surface preparation sqm 56.8 15 852
10 Opening surrounds plaster lm 36.4 15 546
11
furring chanels, 50 mm insulation +
12mm GWB sqm 34.4 50 1720
Total 10,144
Ave Cost Per Sq meter of Façade = 159
Tilt‐up Sandwich Wall Panel outer Leaf
75mm thick + 50 mm Insulation + 150 mm
inner Leaf
SN Description Unit Qunatity
Unit
cost
(AED)
Total
(AED)
11 75 mm 0uter Panel cum 2.58 650 1677
12
50 mm insulation including
connector sqm 34.4 45 1548
Total 11,649
Ave Cost Per Sq meter
of Façade = 182
Tilt‐up Sandwich Wall Panel outer Leaf
75mm thick + 50 mm Insulation + 150 mm
inner Leaf
SN Description Unit Qunatity
Unit
cost
(AED)
Total
(AED)
11 75 mm 0uter Panel cum 2.58 650 1677
12
50 mm insulation including
connector sqm 34.4 45 1548
Total 11,649
Ave Cost Per Sq meter
of Façade = 182
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1 to 10 8,424Same as previous

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Tilt‐Up Villa Case Study
Traditional
AAC
Precast
Panels
T-U with
GWB
Sandwich
Tilt-Up
Cost per SqM of
Façade (AED)
207 257 159 182
% Higher than
Tilt-Up + GWB
30% 62% --- 15%
% Higher than
Sandwich Tilt-
Up
14% 41% -15% ---
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Tilt‐Up Villa Case Study
• Cost savings in addition to material costs
– Shorter schedule = less office & direct O/H cost
– Less working @ heights = less safety prevention
cost
– Less MEP coordination cost
– No forming/shoring = less debris removal cost

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CON/STEEL Tilt-Up Systems, a building program offered by LJB Inc.
www.ljbinc.com
ADDRESS:
LJB Inc.
2500 Newmark Drive
Miamisburg, OH, USA
45342
PHONE:
+1 937 259 2235
EMAIL:
DTomasula@LJBinc.com
map
www.sitename.com
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