Although 37 structures were selected as award recipients, the panel of judges rated eight projects from across all categories to receive the exclusive title, Excellence in Achievement. These projects, detailed in the next few pages, stand out for their unique and inventive use of the Tilt-Up method. One judge commented that this year’s projects show how “award winning architecture is created when talented tradesman are presented with outstanding design concepts.” According to Baty, this year’s Achievement Award winners clearly convey this philosophy and demonstrate that truly successful projects not only highlight architectural and engineering creativity, but also the important role of skilled craftspeople.

 

Excellence in Achievement-

 

AVENTURA TOWN PLAZA:

• Aventura Town Plaza • 44,100-square-foot retail and office facility in Aventura, Fla. • Submitted by Woodland Construction Company of Jupiter, Fla. •

The two-story office/retail facility at Aventura Town Plaza was constructed between existing, occupied retail establishments, placing extreme limitations on space. In fact, the actual square footage of the Tilt-Up panels exceeded the overall square footage of the site, requiring the contractor to perform multiple erection mobilizations and reuse casting surfaces up to four times. Because of the location of the retail space in a busy, downtown area, the mobilization of heavy equipment was limited to nighttime or early on Sunday mornings.

The structure includes several architectural effects, such as cast-in, arched recesses of varying depths; visual dimensional offsets created by varying panel thicknesses; and differing panel heights that create a prominent look for the entry and corner towers. The walkway and center entry, as well as the corner tower features, were originally designed as cast-in-place elements, but were redesigned for Tilt-Up construction due to time constraints and final aesthetics. The curved entry required the use of temporary cast-in leg sections, which were later cut off, to facilitate erection. A porte cachere constructed with 16-inch-thick panel sections was also originally designed as a cast- in-place element. Judges commented that one of the unique aspects of this project was the limitations of the site access, which required extensive coordination and sequencing of the fabrication and erection of the panels. Further, this project clearly stood out because it is an architecturally innovative retail facility.

BOULEVARD AT THE CAPITAL CENTRE:

• Boulevard at the Capital Centre • 500,000-square-foot retail facility in Landover, Md. • Submitted by Chesapeake Contracting Group of Reisterstown, Md. •

The construction of a Main Street-style retail center in Landover, Md., was made far more challenging by wintry weather conditions that required the use of soil cement and ground heaters. Additionally, the ten-building project was constructed in a limited amount of space, necessitating the stacking of panels. Tilt-Up construction allowed the contractor to work within a tight schedule, and the use of Tilt-Up panels facilitated raising the height of the walls for a false second-story appearance. Thin brick, painted PVC, Arriscraft stone and cast-in reveals with accent paint further enhanced the aesthetics of the retail space. Judges noted that the diversity of form and finish on this project clearly dispels all preconceptions that Tilt-Up is a solution only for boxes. In addition, the combination of Tilt-Up with other forms, shapes and materials makes this a truly delightful project.

ERROL & SUSAN RUSSELL HOME:

• Errol & Susan Russell Home • 5,000-square-foot housing project in Edmond, Okla. • Submitted by E.V. Cox Construction Company of Oklahoma City, Okla. •

As an estimator and project manager with more than 36 years of experience working with Tilt-Up, Errol Russell had no problem choosing this method for the construction of his private residence. The panels for the French country-style home were cast and erected in two phases to ensure that no unnecessary trees would have to be removed from the property. The exterior walls were composed primarily of 6- to 8-inch limestone rock, which was over-mortared when the house neared completion. Full- size bricks were also cast into the panels, and a small amount of dry mortar mix was placed in the joints to keep the brick from moving when the concrete was poured.

The fireplace, cast with two Tilt-Up panels, presented a particular set of challenges. The U-shaped panels had to fit together perfectly and present a finish that was consistent with the other panels. In addition, the erection of the second panel proved difficult, as the location of the first panel interfered with the cable release hardware. Further, the mason was initially uncertain about installing the firebrick and damper since the Tilt-Up method had reversed the normal order of installation.

The house includes other distinctive architectural features, such as a rolled-top window on the front of the house that forces the panel line above the roof line, a bay window on a 45-degree angle that was cast so the front panel is supported by two side panels, and a fountain and Koi pond below the bay window formed from three cast panels. With a goal of constructing a Tilt-Up home that did not look like Tilt-Up, this project was obviously successful, remarked judges. This project was deemed award-winning for the embedment of a variety of materials that creates the look of a country cottage constructed of field stone by local craftsmen.

FOSSIL RIDGE INTERMEDIATE SCHOOL:

• Fossil Ridge Intermediate School • 134,000-square-foot educational project in St. George, Utah. • Submitted by Hughes General Contractors of North Salt Lake, Utah. •

The desire to create a structure that would complement the colorful sandstone hills and red soil of southern Utah was a major factor in the Washington County School District’s decision to use Tilt-Up for the construction of the Fossil Ridge Intermediate School. Summer temperatures, which can reach 115 degrees during the daytime, caused concern over the ability to maintain a consistent color and finish from panel to panel. To circumvent this issue, the contractor obtained special permits from the city, allowing concrete pours to begin at 2 a.m. To ensure further consistency, the ready mixed producer stockpiled enough cement powder from the same source for all panels and also kept the same aggregate source throughout the project. Entire wall elevations were poured, corner to corner, on the same day, and all panels were pumped to avoid the inconsistencies in finish that can occur when concrete is placed directly from the chute.

Because the school is located in the vicinity of the recent discovery of dinosaur tracks, two life-sized 30-foot-long dinosaur skeletons were cast into the interior concrete panels in the commons area using a polycarbonate template. These templates gave a slick, almost glass-like finish, setting the impressions off both in color and texture from the standard reveals. The structure also features tapered con- crete columns, which were cast in place using the same colored concrete used for the Tilt-Up panels. Exterior panels were given an anti-graffiti coating, and aluminum joint covers were placed over caulking at the interior panel-to-panel joints to prevent vandalism. Judges noted the innovative use of polycarbonate templates in the dinosaur skeleton cast into the panels as a unique application.

MIAMI CHILDREN’S MUSEUM:

• Miami Children’s Museum • 56,000-square-foot special project in Watson Island, Fla. • Submitted by Tiltcrete, LLC of Medley, Fla. •

The Miami Children’s Museum features several distinctive architectural details, the most prominent of which are the “wave panels” down the central corridor that create a dramatic 40-foot clear height. Because the panels featured randomly placed holes of different sizes, a life-size drawing of these random radii was plotted to assist layout. The building also features perimeter panels with stepped angles, which were colored in varying shades for emphasis. The entry features large cantilevered panels hanging over a glass cone. Because of the limited space available, the contractor relied on casting beds and phased the erection of the panels. The building was tied together with a precast joint system and CIP, which involved a complex coordination of connections. Judges selected this project for the playfulness and complexity of the Tilt-Up panels.

RS+K ADVERTISING OFFICE:

• RS+K Advertising Office • 20,539-square-foot office building in Madison, Wis. • Submitted by Newcomb Construction Company of Madison, Wis. •

When Madison, Wis.-based advertising firm RS + K wanted a unique, distinctive design for their new office building, they knew exactly where to turn. For years, the agency has handled advertising for Newcomb Construction Company, the only Tilt- Up contractor in southwestern Wisconsin. The owners’ desire for a head-turning design brought several complex elements to the project, such as irregularly shaped 8-foot-wide panels with 4-foot offsets for windows. The roof structure provided additional challenges, incorporating a 4-foot-high band of windows directly below the roof and a Douglass fir diaphragm roof deck with a 4-foot roof projection. The structure also features a stair tower formed by eight curved panels surrounding a concrete paved stair for wind-bracing support. To meet the agency’s aesthetic needs, white concrete was used, along with steel cladding, which complements the owners’ collection of motorcycles. Clear glass and clear anodized aluminum framing were used to complement the exterior concrete and steel. Judges selected this project for the intricate panel shapes that remind you of a jigsaw puzzle – an architectural element that is easily accomplished with Tilt-Up and nearly impossible with other construction methods. Further, the blending of construction materials – con- crete with stainless steel “shingles” — was a tremendous success.

SEVEN RIVERS PRESBYTERIAN CHURCH:

• Seven Rivers Presbyterian Church • 40,000-square-foot spiritual building in Lecanto, Fla. • Submitted by Elkins Constructors of Jacksonville, Fla. •

The construction of a sanctuary for Seven Rivers Presbyterian Church was a project 10 years in the making. The congregation, which had previously met in a gymnasium, wanted a structure that would be a source of pride both to parishioners and the community at large. The resulting structure, inspired by French gothic cathedrals, features a 93-foot-high point—the largest Tilt-Up panel erected in the United States to date. Eight smaller points of 50 and 70 feet come together to give the sanctuary a distinctive crown-like appearance.

To deal with space constraints (more than 80,000 square feet of Tilt-Up walls had to be constructed within a 100,000-square-foot area), the contractor cast the 137 panels on site using casting beds rather than the floor slab. New panels were poured on top of existing panels to further save space. To insulate the surrounding schools and residences from construction traffic and noise, a strict 7 a.m.-to-5 p.m. work- day was enforced. The contractor designated special panels (eventually covered by paint or drywall) on which church members wrote Scripture passages and dedications to friends and family members. Judges cited that by incorporating elements of French gothic cathedral design, this project brought Tilt-Up to new heights.

WAITAKERE SPORTS & EVENTS CENTER:

• Waitakere Sports & Events Center • 140,000-square-foot special project in Auckland, New Zealand • Submitted by Alan Reay Consultants Limited of Christchurch, New Zealand •

The Waitakere Council chose Tilt-Up as the method of construction for the Waitakere Sports & Events Center primarily because the use of concrete complied with the Council’s Better Building Code, which includes requirements for Sustainable Design. The choice carried additional benefits as well: The concrete walls provided excellent durability in the sports facility and also reduced the amount of noise carried to surrounding residential areas.

Construction of the four-story facility was a challenge due to substantially varying ground levels. Lower-level panels had to be cast on the upper-level slab, then craned against the timber retaining wall in stacks before being craned to the final location. Access to the lower platform was limited, so erection sequences had to be developed to overcome the problem. The curved Superstructure shape of the building subjected most of the panels to individual design, detailing and lift analysis. Judges commented that a closer look at this building indicated that Tilt-Up was the only way it could be completed economically. For example, the circular panels defining the shape of the end wall were easy to do with Tilt-Up. Finally, judges stated that casting the intricate support system for the bleachers on-site completes the progression of Tilt-Up, from envelope to interior space. Overall, the project demonstrates effective use of the Tilt-Up method.

 

Other TCA Achievement Award Winners-

 

AIRSIDE BUSINESS PARK:

• Airside Business Park • Buildings Number 100 and 200 • Two office buildings totaling 210,000 square feet in Moon Township, Pa. • Submitted by Burchick Construction Company, Inc. of Pittsburg, Pa. •

Originally bid as a conventional steel frame structure with applied precast, the Airside Business Park Buildings were converted to Tilt-Up to meet the specified architectural guidelines, allow the schedule to be expedited, and save the owner approximately $300,000. The tight schedule required the second building, Number 100, to be constructed during the winter months. Since they are located on the airport property, the buildings had to meet sound transmission criteria established by the airport authority. Tilt-Up offered excellent noise abatement, enabling this requirement to be achieved. Further, as the first Class A office building utilizing the Tilt-Up method in the Pittsburg area, Building Number 200 showcased Tilt-Up’s effectiveness in this end-market.

The small building footprint presented unique challenges and necessitate that some panels were stack cask three high. To meet the owner’s strict architectural guidelines, the building featured two colors of textured paint and blue tinted glazing on the windows. Further, multiple size blocks were used as a textural and depth-contrasting veneer. To create an ornamental focal point for the office park, a decorative Tilt-Up clock tower structure was constructed. Using Sobotec panels, an eyebrow accent was created at the roof level and the main lobby ceiling.

AMATROL:

• Amatrol • 80,000-square-foot office and warehouse production facility in Jeffersonville, Ind. • Submitted by AML, Inc. of Floyd’s Knobs, Ind. •

Amatrol selected Tilt-Up for the construction of their new facility because the method was cost-effective to construct, durable and aesthetically appealing. One of the most challenging elements of this project was the curved panels. The erection and connection of these panels, some of which weigh 13.5 tons, were effectively held in place by a cantilevered connection. The connection detail was designed to allow for expansion – an important component for the owner – but it was very difficult to execute during erection since the panels were to “hang” off of the connections. To add to the difficulty, the curved panels were attached to round columns that made it very difficult to take measurements and connections had to be made in a confined area.

Careful consideration was taken to the design of the front elevation. The curved architectural feature creates an elevated conference room that allows for the much-desired panoramic view of downtown Louisville. To accomplish this, the architect used the combination of curved Tilt-Up concrete panels, blue colored glass and concrete columns. By elevating the conference room, it allowed the main entrance to become part of an elaborate curved projection. For the exterior of the facility, the owner wanted natural and neutral colors. As such, varying shades of beige were used as the field and accent colors. The corporate color of navy blue was utilized in the reveal line to accentuate the shades of beige. The blue glazing of the large curtain walls and storefront maintains the accent.

BOYS & GIRLS CLUB – TEICHERT BRANCH:

• Boys & Girls Club – Teichert Branch • 32,538-square-foot special project in Sacramento, Calif. • Submitted by Panattoni Construction of Sacramento, Calif. •

Although the owner was unfamiliar with Tilt-Up, the Teichert Branch of the Boys and Girls Club selected the method for its cost-effectiveness and design flexibility. This project represented the culmination of 10 years of unwavering commitment between the local community members, businesses and other contributors who donated their services and time to bring vitality to this south Sacramento neighborhood. Equipped to serve more than 10,000 young people living within a two-mile radius of the club, the facility was designed and built specifically for youth programs and activities. The interior space accommodates classrooms and centers for computer education, library learning, science and teens. Further, the facility also houses the Kid’s Café, gymnasium, community multi-purpose room, kitchen, main activities game room and administrative offices. The exterior includes a covered patio that overlooks a soccer field and vegetable garden.

The design scheme included the use of bright, energetic and youthful colors. Acoustical wall panels as well as perforated and insulated decking were used to minimize noise in the open-air environment. Extensive use of glass and glazing ensured lines of sight that resulted in child and employee safety. Architectural treatments and features included arches at the panel parapets, selected use of reveals for external color breaks, exposed metal roof deck, roof trusses, curved wall panels and a two-story lobby with extensive use of sheetrock and reveals.

BRIGHT HOUSE NETWORKS:

• Bright House Networks • 166,000-square-foot office building in St. Petersburg, Fla. • Submitted by Seretta Construction, Inc. of Apopka, Fla.•

Speed of construction was of the utmost importance for this project because the owner had outgrown the space they were leasing and needed to improve the efficiency of their communication and operation with various internal departments. In order to meet the deadline, the project had to be ready for occupancy in just 12 months. Through the design-build approach, Tilt-Up was introduced as the solution to meet the building requirements and schedule. Tilt-Up provided a cost-effective means for the end-user to build and purchase a customized facility that would allow them to consolidate five separate divisions into one location instead of leasing a larger office building and paying the costs associated with interior build-out.

Innovative architectural applications allowed for a high quality Class A urban office building in a premier business park. Existing buildings in the park are traditional brick; however, this material was too expensive for the owner’s budget. Tilt-Up panels with cast-in-place thin brick afforded the owner an opportunity to build in an upscale business park while keeping with the development’s existing theme. False joints were created between each color of brick and corner return bricks were set on the outside edges of each corner panel and all window openings to achieve the look of a true brick building. Creating the false joints required eight brick cuts per row, which was an extremely labor intensive process and required flawless precision.

Special panel design was implemented to accommodate large openings for the internal loading docks. Single- legged panels with 34-foot wide openings were erected and placed at the pilaster of corner panels. Large openings and the height of the panels required strongbacks to provide extra support while standing the 70- ton panels. Trees on the site restricted full crane access around the building. Panels for the north side of the building had to be picked and walked backwards with the crane from the east side of the building.

BUSINESS EXCHANGE:

• Business Exchange • 50,000-square-foot office building in Lee’s Summit, Mo. • Submitted by CON/STEEL Tilt-Up Systems of Dayton, Ohio.•

The major tenant, Meyer Brothers Building Company, needed a new facility to locate its business office. Since Tilt-Up construction is a major component of Meyer Brothers work, the developer agreed to build a Class A office building – the first in the Lee’s Summit community –that would serve as a showcase for architectural Tilt-Up construction. The use of two different types of exposed aggregate, cast-in thin brick, cast- in thin block and painted finishes combined to provide a useful sales and marketing tool for both the construction and development business.

The height of the panels plus the numerous exterior accent panels required special attention to sequencing of panel construction on the relatively small floor slab. The radiused entrance panel is concave, meaning curved into the building structure. Composite floor framing provided an economical system to maximize clear height while minimizing overall building height to meet local and Federal Aviation Administration regulations. Accent panels with various architectural treatments surround the perimeter of the building and are offset from the exterior face at varying depths. Two-inch recesses were cast into the panel to allow for application of cast- stone sills. Spandrel glass was incorporated in the recessed portion of the building’s side and rear walls. A two-inch fascia wythe was cast using integrally colored concrete and structurally bonded to the main structural panel wythe. In order to achieve the masonry treatment on all sides, two identical panels were cast with the face shells and set back-to-back. This required precise control so that all openings and masonry joints would align. These panels also include several large openings, with 90-degree return pieces along every edge and jamb.

CARY CHRISTIAN SCHOOL:

• Cary Christian School • 27,360-square-foot educational facility in Cary, N.C. • Submitted by Citadel Contractors, Inc. of Apex, N.C. •

The school required occupancy within nine months from the start of construction, which ruled out masonry or precast on schedule constraints prior to price considerations. This very aggressive schedule required a detailed critical path of scheduling to accommodate and provide efficiency for this fast track project.

One of the main challenges for this project was the lack of casting space, resulting in stacking and casting slabs. The front entrance panel weighed 119,230 pounds, was more than 71-feet tall and was placed on 27-foot poured-in-place columns with 24 lifting points and six braces. To increase the complexity of this panel, it included deep reveals and a crucifix feature that represented the origins and beliefs of the school. Further, the entrance was topped with an intricately detailed gable and finished with concrete beams that tie the gable back to the structure. Both thin brick and a coating were used as architectural treatments. Further, the natural beauty of concrete was accentuated in the design. The windows feature intricate, cast-in-head and sill details. The quoins add to the architectural style with their clean solid look.

CORNERSTONE FELLOWSHIP CHURCH:

• Cornerstone Fellowship Church • 110,000-square-foot spiritual building in Livermore, Calif. • Submitted by Balch Enterprises, Inc. of Hayward, Calif. •

The Cornerstone Fellowship church needed a new facility that would accommodate their growing congregation and scope of services, activities and community reach. Recognizing the challenge associated with raising funds for a new religious facility, the contractor presented the idea to redevelop a vacant 62,000-square-foot indoor sports facility to meet the church’s needs.

Constructed in the early 1990s, the original structure used load-bearing Tilt-Up wall panels. Therefore, the building had few interior columns, allowing the design team to transform the majority of the original structure into a 2,000-seat sanctuary with the help of seating structures cast inside the facility with Tilt-Up techniques. By relocating two 70,000-pound Tilt-Up walls panels, the team easily added 14,000 square feet to the building footprint which today comprises a stage and event area, nursery, classrooms and a youth center. Further, with the construction of a 34,000- square-foot second floor containing additional offices and classrooms, the facility is now about 110,000 square feet in size. A 10,000-square-foot courtyard dramatically upgraded the image of the facility, allowing congregants to feel like they are more a part of a neighborhood than an industrial setting.

ERIC GOODWIN PASSAGE:

•Eric Goodwin Passage • 400-square-foot special project in Charlottesville, Wa. • Submitted by Dayton Superior Corporation in Miamisburg, Ohio. •

Members of the Tilt-Up Concrete Association assisted architectural students and faculty from the University of Virginia in the creation of a site cast Tilt-Up Memorial to a student. The Memorial honors Eric Goodwin, a member of the class of 2002, who passed away during his final year or study at the School of Architecture. Designed to provide outdoor classroom space, the Eric Goodwin Passage is located on a tight site in the Campbell Courtyard across from Campbell Hall – the building that houses the School of Architecture. Comprised of two site cast Tilt-Up panels, there is a passage space between the two walls. The passage space is aligned with a tree memorializing Carlo Pelliccia, an admired professor at the school. One of the walls is vertical and the other is slightly tilted with braces. This project demonstrated the architectural expression that is afforded through the use of Tilt-Up, as well as served as an educational tool.

The project was made possible through donations made to the Eric Goodwin Memorial Fund, the Bruce Ford Brown Charitable Trust to support faculty and student design-build projects at Campbell Hall, and through the donations of Allied Concrete, Inc. and the Dayton Superior Educational Fund. Further, Dayton Superior donated the consumable products that they manufacture and lent the University their re-useable products for the project, as well as arranged for their local dealer to donate the reinforcing steel.

EXCEL ACADEMY CHARTER SCHOOL K-8:

• Excel Academy Charter School K-8 • 44,000-square-foot educational facility in Arvada, Colo. • Submitted by Saunders Construction, Inc. of Centennial, Colo.•

The efficiency of Tilt-Up allowed the building to flow better during construction, resulting in reduced cost and the effective addition of more area. The project began in the middle of January and needed to be open in late August. Tilt-Up allowed for the exterior to be up fast and enclosed so the contractor could focus on the finishes inside. The limited slab space required two separate pours for the panels.

The creative, angular image exhibited by the school’s architecture is reflective of Excel’s learning style in the classroom. The main walls separating the wings of the school were all exposed Tilt-Up, which significantly reduced the use of structural steel framing. Panels had a variety of shapes filled with formliners, most of which were recessed into the panels. Reveals were laid out at irregular angles, yet flow seamlessly from panel to panel. The darker colored paints used at the formliner areas create a visual depth to the already recessed panels. This, in contrast to the lighter field beige color, allows the panel’s articulation to stand out. Also, the architect did recesses within recesses making some panels look like they were separately formed panels welded together. The most interesting aspect of the design was the trapezoidal shaped panels for the gymnasium. Another interesting attribute was the use of Thermomass insulation for the gym panels, which provided a durable surface capable of withstanding abuse during athletic events and a thermally efficient envelope.

Most of the exterior panels were very irregular in shape creating an assorted array of parapet elevations. There are numerous “layers” of panels with different parapet heights creating a very “busy” look. At outside corners, the architect designed the intersection of the panels at angles less than 90 degrees and then forced the top of the panels to slope toward the corner. This posed a challenge when forming the two panels that would marry to create this corner. The geometry needed to be exact through checking degrees of angles and panel heights before placing the concrete.

FLORIDA ATLANTIC UNIVERSITY STUDENT SUPPORT SERVICES FACILITIES:

• Florida Atlantic University Student Support Services Facilities • 101,202-square-foot educational facility in Boca Raton, Fla. • Submitted by Woodland Construction Company of Jupiter, Fla.•

Providing an architecturally appealing structure that complements existing facilities on the Florida Atlantic University campus, Tilt-Up was selected for this project as it provides the University with the look, quality, durability and cost-effectiveness they desired. Demonstrating the viability of Tilt-Up in the higher education market, the method was able to cost-effectively meet the University’s needs. The Student Services Support Center provides more space for important offices and demonstrates a commitment to helping students.

The Tilt-Up panel interaction with radius cast-in-place walls, curtain walls, second floor and roof structural steel made this a very difficult project to layout. This necessitated precise layout to ensure that all phases of this project came together correctly. Temporary legs were used to erect panels that had large openings. A radius retaining wall was used to support the glass curtain wall system, which tied into the Tilt-Up system. A semi-circular walkway is wrapped around the interior of the building and contoured stairs on the inside lead to the exterior. The neutral color scheme complements the existing facilities on the campus, while the use of tinted glass allows the facility to stand out on the expansive campus. Beige colored panels were placed behind larger Tilt-Up panels to provide a dimensional look and relief to the large building. Further, intricate reveal patterns were used throughout the building. Textured paint was utilized on the exterior of the facility.

GLENN OFFICE BUILDING:

• Glenn Office Building • 39,497-square-foot office building in Woodbridge, Va. Submitted by Citadel Contractors, Inc. of Apex, N.C.•

Displaying the strength and architecturally appealing characteristics of Tilt-Up, the Glenn Office Building needed to represent the design style of an adjacent structure. The project featured a variety of architectural treatments including quoins, dentils, brick, window treatments, a canopy and columns. These detailed features in the concrete are clean and provide a striking appearance. Tilt-Up retaining walls are backed up with load-bearing stairwells to provide the required stability. Further, the retaining walls were utilized to accommodate 12- inch grade changes.

HARMONY HIGH SCHOOL:

• Harmony High School • 276,339-square-foot educational facility in St. Cloud, Fla. • Submitted by TILT-CON Corporation of Altamonte Springs, Fla.•

Tilt-Up was the best option for meeting this project’s needs including speed, economy and durability. The complex job involved several challenges. Environmentally, the job site property was located partially on wetlands and partially on a dry, desert-like piece of land. As a result, the site was either muddy or dusty much of the time. To help alleviate this, the team constructed a series of temporary moats and ditches to handle the drainage after rainstorms. On dry days, workers donned protective dust masks. With the closest source of concrete more than 45 minutes away, the team overcame another challenge by carefully scheduling early morning pours, some as early as 2 a.m. A third challenge was the tight job site, which was handled through unique and carefully designed casting slab placements and maximum use of the main slab. A higher strength ready mixed concrete was used in all wall panels and the gymnasium walls were hardened and constructed as a hurricane shelter.

The uniquely designed panels feature an attractive ribbed finish. The peaked roof system of the administration building makes it stand apart from the typical institutional structure. Formliners were used to make depressions and an interesting pattern on the outside walls. These patterns had to be carefully matched between each panel. This eight building complex was completed within 20 weeks and opened on time for the new school year. The campus includes eight separate buildings connected by covered walkways and accented throughout with concrete planters and features. The classroom building is two stories and the gymnasium is higher than a typical structure of its kind. The campus also includes a full-size auditorium.

HOGAN OFFICE BUILDING:

• Hogan Office Building • 21,500-square-foot office building in Centerville, Utah. • Submitted by Hogan & Associates Construction of Centerville, Utah. •

Desiring a durable facility that offered aesthetic value, Tilt-Up was selected for this project because it met the city’s strict ordinance for the business park and would allow Hogan & Associates to market concrete to visitors of their facility. Further, Tilt-Up is considered a “green” product that would be locally produced and would offer the thermal mass needed to heat and cool the building through our ground source mechanical system. Forced out of their former office space to make way for a freeway, construction began in late fall with the structural work beginning in the dead of winter. A portable boiler was used to control the winter temperatures, which allowed work to continue through the worst part of the winter and complete the structural walls and the mural despite heavy snowfall. Construction also required careful management to ensure the timber frames were compatible with the concrete work.

The architectural treatments were a rough bark wainscot around the entire building (except the mural wall), a simple chamfer pattern, a mixture of timber frame elements and concrete, exposed aggregate accomplished through concrete retarder, and a standing seam metal roof. The concrete was kept a plain color to retain a natural and durable look. Design elements in the wall include a formliner, a mural depicting construction elements, exposed aggregate, and exposed interior walls.

HYLA U.S.:

• Hyla U.S. • 11,000-square-foot office building in Deerfield Beach, Fla. • Submitted by Kenneth R. Carlson – Architect, P.A. of Deerfield Beach, Fla.•

Creating a corporate office facility to entertain foreign clients and impress them with the corporate image of quality was an important goal of the German-based Hyla Company. Tilt-Up provided the owner with a strong, durable and watertight facility that offered crisp edges and smooth panel faces. This was a small building on a tight sight, which allowed for limited crane movement. As a mixed-use facility offering both office and warehouse storage space, occupancy separations were naturally created by the Tilt-Up panels.

Recognizing that block and granite was cost prohibitive, a simulated granite panel wainscot was used to make the project affordable. The simulated granite panels were created with reveals and multiple layers of textured paint. Porte cochere was cast in four pieces and tilted as one component. Additional architectural features included balcony projections with Tilt-Up deck and floor panels, as well as tower panels articulated with simulated granite wainscot with bold, rounded window openings to create a striking clean and crisp elevation.

JOHN A. FERGUSON SENIOR HIGH SCHOOL:

• John A. Ferguson Senior High School • 310,023-square-foot educational facility in Miami, Fla. • Submitted by Johnson Structural Group, Inc. of Deerfield Beach, Fla.•

Building a strong sense of community and identity within a large state-of-the-art educational facility was one of the main forces driving the design of this project. The decision was made to organize the school around two distinct courtyards in order to accommodate the extremely complex facility that included separate bus and parent drop-off areas; athletic fields; classroom space for almost 3,000 students; common areas comprised of an auditorium, gymnasium, cafeteria and media center; administration and student guidance suites; as well as music, art, and vocational labs.

Because of the difficult program requirements including different ventilation requirements and square footages for each type of room, there were no standard panels on the project. The well-defined entrances to the school, each unique in its massing, shape and color, are scaled appropriately in accordance with the building’s organizational hierarchy. The main entrance, with its rounded pilaster and beams, allows students to pass nearby a massive Tilt-Up panel textured with formliner. At the parent drop-off entrance, the corner of the building is “peeled” back using a double thick panel at the base and single thickness panel at the top. The auditorium’s broken, angular parapet draws the eye from the courtyard, as does the outdoor stage, also cast with splitface concrete block formliner. Playful elements like the art patio and child-care lab patio, with their random glass block patterns, act as a contrast to the powerful walls of the three-story classroom building. Formliners used in specific locations provide for accents at vertical circulation elements in the three-story building as well as an accent band at the gym. In an effort to humanize the scale of the building, different accent colors were used for each wing so that students can refer to the blue, green or yellow wings when walking from class to class. A split-face block formliner, as well as different combinations of glass block, storefront glazing systems, and Tex-Cote, were among the finishes applied to the school.

JOST CHEMICAL BUILDING II:

• Jost Chemical Building II • 101,750-square-foot warehouse/distribution facility in Bel-Ridge, Mo. • Submitted by The Korte Company of Highland, Ill. •

Tilt-Up was selected for the Jost Chemical Building II for a host of reasons including speed of delivery, elimination of interior ledges and the necessity of a facility that complements the owner’s current building adjacent to this project. The new facility was necessary to meet current and future production demands, but the owner also wanted a building that conveyed a striking architectural statement. The single property would be responsible for housing both corporate offices as well as warehousing and shipping demands.

The design incorporates both smooth and dimple textured panels, reveals and accent bands within the Tilt-Up panels, and is enhanced with angular walls of concrete and silver reflective glass curtain wall elements. Finished with a light gray, medium gray and burgundy color scheme, the panels match the adjacent existing facility. Additional freestanding Tilt-Up walls screen the truck loading area from the street to form a backdrop for a landscaped employee break area. A metal clad canopy and special shaped metal columns define the entry. The office area incorporates a two-story atrium that is capped with a 14-by-50-foot translucent panel skylight, which provides natural lighting for the inner portions of the office area. Additional light is provided through clerestory translucent panels around the perimeter of the atrium space. A 12-foot high granite panel waterfall adds drama and a soothing auditory sense of balance to the atrium area. Additionally, 12-foot high ceilings add to the open feeling of space throughout the office areas. The interior space is finished with custom designed glass and a custom railing system at the atrium opening. Special wall coverings, custom wood millwork, porcelain tile floors, patterned carpet tiles and accent painted walls further enhance the strong corporate image. During the evening, the entire façade facing the street is illuminated with wall sconces, bollards and accent floodlighting.

LOGRO-CONFICORP:

• LOGRO-CONFICORP • 274,500-square-foot manufacturing/industrial and warehouse/distribution facility in Tepotzotlan, Mexico • Submitted by IN3 of San Ysidro, Calif.•

Although the client had the perception that Tilt-Up was a high-cost technology, IN3’s team was able to show the owner that it was the best solution for meeting their goals, which included a durable and aesthetically appealing facility that would attract world-class tenants to the Mexico City area.

The building-land ratio of almost 60 percent presented unique challenges. This necessitated heavy earth movements and created a lack of working space outside the platform area. Schedule concerns relating to the rain season forced IN3 to cast only perimeter bands of the concrete floor to provide space for Tilt-Up forming and casting. High humidity and afternoon storms resulted in insufficient floor area for panels to be placed. This problem was solved by stack casting panels three high. FDA requirements to keep building coves as clean as possible required the Tilt-Up panels to be load-bearing elements on all four sides.

Since the client’s corporate offices are located at the facility, office modules had to be flexible and elegant. Wanting to accurately reflect the monetary investment of the facility, the owner decided to avoid the image of a gray box. As such, soft and warm colors were select- ed to give elegance and contrast to the blue windows and Alucobond accents. Four different colors were used and the band-like design helped provide continuity between the big box and the three office blocks. Heavy use of reveals helped enhance employee access and the curved wall appearance was obtained with small degree angled edges for panels at the office blocks front façades. All minor buildings and screen walls throughout the project were built with Tilt-Up panels. At the building corners, Alucobond and reflective glass were used to articulate the 45-degree corners to maximize the use of land.

LOUISVILLE METRO COMMERCE CENTER:

• Louisville Metro Commerce Center • 517,000-square-foot warehouse/distribution facility in Louisville, Ky. • Submitted by Kovert Hawkins Architects of Jeffersonville, Ind. •

With the goal of constructing a state-of-the-art distribution facility, Tilt-Up was selected for its architectural flexibility, speed of construction and cost-effectiveness. The architectural detail and first-class landscaping create a distribution center with the appearance of a Class A office facility.

Constructed at the Old Louisville Motor Speedway site, extensive demolition and challenging site conditions added to the complexity of the project. The facility offers a tan and green color scheme and is highlighted through the use of glass, aluminum framing and an upgraded paint system. A two-story curtain wall accented with aluminum perforated panels adds an increased level of detail at entry points. Stand-alone architectural Tilt-Up panels highlighted by decorative aluminum and steel were used to accentuate the corner entrances. Special architectural treatments include perforated anodized aluminum panels, a two-story glass curtain wall and galvanized ornamental steel fabrications.

MAPLEWOOD CENTER:

• Maplewood Center • 48,000-square-foot retail center in Jupiter, Fla. • Submitted by Woodland Construction Company of Jupiter, Fla. •

Originally designed as a masonry project with wood siding nailed to the structure to create the desired “Key West look,” the switch to Tilt-Up with cast-in formliners provided the owner with a tremendous cost savings and more durable structure that is maintenance-free. Further, this solution created solid concrete walls with no attached siding. In a wind environment, like Florida, this is an added benefit because the owner does not have to worry about siding coming off during a hurricane.

This building had an unusual shape with towers and breezeways. The panelization of this project required extensive coordination and sequencing in order to tie in the corner tower features and covered walkways with the main building structure. The towers contained four panels, two of which cantilevered over the main building and down to the foundation with return leg sections. Once these were together, they created a cast-in-place column look inside and outside the building, as well as the structural “box” required for the overall stability of the building. To achieve the desired Key West look, it was necessary to use cast-in formliner, which is typically only used as an accent, for the entire build- ing. This required extensive coordination and attention to detail.

The standing seam metal roof also meets the design requirements for area and the pastel color scheme blends in with existing facilities. Around the windows, there is a solid band of color that is a few shades darker than the majority of the building’s exterior to provide a dramatic effect similar to wainscot. The towers and atypical shape break up the building and provide space for breezeways. Columns separate the retail storefronts and provide each tenant with a clear space that is their own. Further, this facility stands out from traditional “strip centers” in the area, because of the use of two-story towers.

OWENS BROTHERS CONCRETE BATCH PLANT:

• Owens Brothers Concrete Batch Plant • 5,600-square-foot manufacturing/industrial facility in Aurora, Colo. • Submitted by CON/STEEL Tilt-Up Systems of Dayton, Ohio. •

Since the operations of the building required a durable facility, the owner switched from a metal building to a concrete structure that enabled them to comply with city ordinances. The city required that the entire batch plant operations be enclosed within the building. Also, the manufacturer of the equipment would not allow any part of the enclosure to be in contact with the building. Because of this, the team used 3-D modeling to help fit equipment into tightly designed tolerances. The aggregate bin and cement silo/mixer were erected previously because of their heights. This required that the panels and roof structure were erected around them.

The city selected the color scheme of the project to provide a southwestern appearance – sandstone rose with blue metal roof panels. Since the original design called for metal wall and roof panels, the concrete panels had metal panel profile cast into the panels at the upper sections of the aggregate bin enclosure. The building features stacked panels that reach a height of 66 feet-3 inches to enclose the aggregate bin. Removable roofs were used for servicing the aggregate bin and batch drum replacement. The mechanization that was designed into the project allows the plant to be operated by one person on slow days.

PEAKWAY MARKET SQUARE:

• Peakway Market Square • 60,987-square-foot retail center in Apex, N.C. • Submitted by Citadel Contractors, Inc. of Apex, N.C.•

Tilt-Up was selected for this project for its cost-effectiveness and speed of construction. The goal of this project was to create a shopping center that is varied in massing and materials to accommodate the planned mixed-use. One of the most difficult challenges of this project was coordinating the multiple brick patterns and four brick colors. Additional challenges included the numerous curved surfaces, panel configuration, and the complex reveal patterns that align with the windows. Demonstrating the ability of Tilt-Up to excel in multi-story mixed-use developments, this project utilizes a diverse range of architectural treatments including a mix of brick and painted concrete surfaces, EIFS cornices that are applied to panels, and a curved central drum element that is set on Tilt-Up columns.

THE POINTE @ WELLINGTON GREEN:

• The Pointe @ Wellington Green • Six retail buildings totaling 78,300 square feet in Wellington, Fla. • Submitted by Woodland Construction Company of Jupiter, Fla. •

Comprised of six Tilt-Up buildings with arched entrances and intricate reveal patterns, this facility creates additional retail, professional office and restaurant space for the growing community. The new retail outlet needed to blend in with the existing large indoor shopping mall and had to provide a Mediterranean look to meet the strict design requirements of the city.

The square footage of the panels exceeded the square footage available. As such, one central location was created for the casting bed and panels were transported via a crawler crane to their proper location. Multiple castings were completed on this bed. Large openings in the arches gave this project a high level of complexity. Ceramic tile inserts, canvas awnings, and brick paver walkways were utilized to create the Mediterranean look. Molding and cornices were applied at the top of the towers with EIFS and a covered walkway surrounds the entire retail center. To economically dress up the finishes of the building, decorative tile inserts were incorporated into the cast-in recesses and EIFS was used in certain areas. Code requirements necessitated the neutral beige color scheme and a circular window in the tower creates striking architectural appeal. Cast-in reveals provided a cost-effective method for achieving the desired look. A Tilt-Up retaining wall was used to protect a wetland from the construction process, which demonstrates the entire construction team’s commitment to being good stewards of the earth.

REX WELLNESS CENTER:

• Rex Wellness Center • 30,000-square-foot care center in Garner, N.C. • Submitted by Citadel Contractors, Inc. of Apex, N.C. •

Well received by both the community and its owners, the goal of this project was to provide a cheerful and pleasing facility to enhance the services of Rex Wellness. Tilt- Up was selected for this project because of the method’s ability to meet the owner’s schedule and budget while providing superior design. The contractor was able to demonstrate that Tilt-Up was the solution for this project, even though it had a small footprint, was multiple stories and required natural light and many clear spaces.

The pool complex with a exercise room above it created several challenges including loading and climate control. Corrosion and climate control issues were solved with insulated panels supporting a ceiling of double tees. The all concrete pool structure provides a tight corrosive resistant environment. Vibrant colors with out- of-plane panels and strategically placed windows create a unique look. Entrance canopies were built with curved panels and intricate supporting brackets. This facility capitalizes on the natural beauty of concrete since it is the only material used.

ROTH DISTRIBUTING COMPANY:

• Roth Distributing Company • 42,00 square foot facility in Aurora, Colo. • Submitted by Intergroup Architects of Littleton, Colo. •

In order to meet the business park’s stringent design guidelines, as well as create the optimal facility in terms of durability and versatility, the own selected Tilt-Up for this new building. Tilt-Up was instrumental in meeting the tight budget while allowing enough design versatility to achieve the warmth and street appeal desired on the exterior of the facade.

The design team was challenged with merging and integrating the previously separate functions of the corporate office headquarters, regional design showroom, technical service training facility and regional distribution warehouse. A tight budget, strict business park guidelines and an irregularly shaped site further complicated this task. Extensive programming was done to develop a design that gave prominence to the showroom and made efficient use of the second story of the office headquarters. The design was softened and brought down to a smaller scale with extensive detailing on the exterior of the panels. Panels had a decorative reveal pattern, textured three-tone paint finish and adhered sandstone veneer in two native colors. Additional detailing was provided by a standing seam metal roof covered entry element, sandstone veneer columns, ornamental steel trellis canopy, glass block and colored storefront window system. Extensive landscaping and custom exterior lighting fixtures were used to accent the building. The two-story glass block metal canopy and decorative steel trellis at the main entry helped to create a bright and welcoming entrance to the design showroom.

ST. AUGUSTINE ST. JOHNS CO. AIR TRAFFIC CONTROL TOWER:

• St. Augustine St. Johns Co. Air Traffic Control Tower • 5,400- square-foot special project in St. Augustine, Fla. • Submitted by Steinbicker & Associates of Dayton, Ohio. •

Speed of construction was certainly the primary factor for the air traffic control tower constructed on the eastern edge of the St. Augustine-St. Johns County Airport. Tilt-Up was select- ed as the solution because of the method’s ability to meet demanding schedules and budgets, and even more important – durability and resistance to everything from hurricanes to bombs. Previously, the typical construction method for aviation towers has been cast-in-place concrete, reinforced masonry, or a combination of the two; however, Tilt-Up was adopted for this project to meet the schedule and budget.

The original design concept included four full-height panels for the tower. But, the size of crane necessary to erect the huge panels, as well as the limited bracing area, necessitated an alternative solution. As such, the panels were divided vertically, which created eight 12-inch thick panels approximately 25-feet wide and 20-feet tall for the tower. Each panel weighed approximately 85,000-pounds each. Innovation was not limited to the design process, but applied during construction as well. The first four panels were tilted into place, and then two concrete floors – constructed on the ground – were slid down into place, one at the 10-foot mark and the other at 20-feet. The next four panels were then tilted into place on top of the original four panels and braced to the second floor slab. The remaining two floors slabs were then dropped into place at 10-foot increments. The benefit to this system is the use of a smaller crane and braces, as the braces never had to handle more than 20-feet of panel. The cap – the control tower also was constructed on the ground – was simply lifted as one piece into place. The tower was designed for maximum durability – to include 125 mile per hour wind load and exposure category D with an importance factor of 1.15, meaning that this tower should not only stay intact during a hurricane, but operational. Exterior stucco and roof colors were selected to blend in with the architecture of the city and surrounding community.

SMALL BUSINESS ADMINISTRATION:

• Small Business Administration • 81,000-square-foot office building in Citrus Heights, Calif. • Submitted by Panattoni Construction, Inc. of Sacramento, Calif. •

Tilt-Up was selected for this project because of its durability and ability to be able to be utilized in the construction of a Class C Federal Building. Class C Federal Buildings have exterior impact requirements that need to sustain impact of a moving 4,000-pound vehicle at 30 miles per hour and resist interior and exterior bomb blasts up to 100 pounds of TNT or its equivalent. The Small Business Administration (SBA) needed a building that would withstand little or no damage from a terrorist attack, or acts of God, and enable the user to maintain its national base of operations and the ability to mobilize to aid those who had been affected by national catastrophes.

The design and installation of the glass and glazing systems were challenging due to the implementation of the blast and impact loading requirements. This was uncharted territory for the design team. Interior finishes were also challenging because of the intricate level of interior design features for the break room ceiling and flooring system. The acoustical ceiling panels were suspended in a series of oval shapes to represent clouds and the floor patterns were designed to mimic the ceiling. In addition, a commercial grade roll-up was installed in the break room to conceal the specialized “restaurant style” kitchen appliances that are used for major functions. The second floor has two very large oval skylights that maintain the cloud theme as well as a specialized interior storefront style window system with a writeable surface for the War and Conference rooms, the Area Director, and Deputy Director’s offices. In addition, the exterior glass and glazing systems are designed with bulletproof resistant features per the requirements of the Federal Government. Architectural treatments include the use of earthtone and neutral colors, seat walls and fountains for building protection, as well as a glass curtain wall and extension hardscape.

THE SONIC BUILDING AT BRICKTOWN:

• The Sonic Building at Bricktown • 105,600-square-foot office building in Oklahoma City, Okla. • Submitted by E.V. Cox Construction Co. of Oklahoma City, Okla.•

Cost evaluations for this project clearly showed Tilt-Up to be the most economical method available. Further, Tilt-Up was able to meet the owner’s budget, schedule and rate of return required to make the project feasible. This facility is located in an existing business district comprised of load-bearing masonry buildings constructed more than 40 years ago and the new facility had to be compatible with the aesthetic requirements for the district including a masonry exterior. Samples of coated Tilt-Up panels were provided to show that the Tilt-Up would appear as cast stone when viewed. The building is located 36-feet from a canal on one side and sits adjacent to a busy street on the other. Crane access required construction of an engineered fill temporary road at the canal side for access.

The tenant’s sign required an additional 46-foot by six-foot panel to be set on top of the finished wall. Each of the two sign panels was set on top of the typical wall panels using a pipe and sleeve arrangement that required extreme precision to line up the four affected panels. Insufficient floor space for pouring the panels required stack casting. Full-thickness masonry brick veneer and cast stone accents were used on floors one through three and the fourth floor is exposed Tilt-Up with a precast corbel sitting atop the concrete panel at the roofline. Copper roofing accents the entry to the main lobby. Reveals and patterns cast in the panels at the fourth floor mimic cast stone. Huge windows created panels with an extreme amount of open area for their size and height. Stainless steel embeds were used for attachment of cast stone to minimize any future corrosion and staining of the building exterior.

STANDARD SALES COMPANY, L.P.:

• Standard Sales Company, L.P. • 68,191-square-foot warehouse/distribution in Odessa, Texas • Submitted by HDA of St. Louis, Mo. •

Located along the front range of the Rocky Mountains, this beer distribution facil- ity replaced an existing building. The owner preferred a design that was cohesive with Anheuser-Busch’s 1870’s Brew House in St. Louis, Mo. yet would easily tie into the surrounding natural terrain. Close coordination with the City of Littleton also was key to project success.

The end-result was a facility that features auburn brick, limestone and a mahogany wooden ceiling with trusses. Accented stained concrete floors welcome visitors into the lobby, which is designed to be multi-functional and allow for large gatherings outside the hospitality suite. The warehouse has an exterior brick column at 40-feet-on-center to give relief to the large panel. The office has a metal- sloped roof to screen the rooftop mechanical units and a ridged entry extended into the lobby featuring wood timber beams and ceiling. Brick veneer was used to match the modular brick.

TEMPLE DOR DORIM:

• Temple Dor Dorim • 21,500-square-foot religious facility in Weston, Fla. • Submitted by CON/STEEL Tilt-Up Systems of Dayton, Ohio. •

With the goal of constructing and developing a worthy house of worship that evokes pride from the congregation, Tilt-Up was selected for this project for its cost-effectiveness and strength. A section of the building features a domed roof that projects above the surrounding structure. Four panels with slender legs support four spandrel panels, creating an octagon in plan. The eight panels have louver openings and support radial steel arched trusses creating the roof dome. The architect wanted a very low profile for the building, which is an addition to an existing building. An “epicore” concrete deck was used for the roof surrounding the dome – ensuring maximum clear height with minimum depth of structure. Tilt-Up panels were hung on the side of the round concrete columns at the covered canopy along the social hall and columns were formed round at the bottom (the visible portion) and square above (hidden behind the soffits) to simplify panel connections.

A variety of architectural treatments were used to create the desired look including integration of the clerestory within Tilt-Up, radius and coffered ceiling features, as well as a dome ceiling. Extensive casework throughout is evident through the use of marble floors and stone walls. A wood canopy at the entry extends through the curtain wall and into the building. Arriscraft stone veneer wraps the panels at the front entry and extends into the building.