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TC Ball Cup Manufacturing Facility

Summarize the project's program, features and achievements.

The new 240,000 sqft manufacturing facility will be the first of its kind producing for the TC Ball Corporation. This facility will be used to create the first aluminum Solo cups. This tilt project is in Rome, GA. This facility had many numerous logistical challenges to overcome to achieve the owner's desired schedule, as the equipment delivery dates were already set. Due to sloping slabs, pits, trenches, and very large equipment foundations that had to be in place most of the tilt was caste on casting bed. The project itself included 240,000 sqft of reinforced SOG ranging from 8" to 12" thick. The building featured 97 tilt panels ranging from 8" to 11.25" thick. The project included two structural pits. The pits were surrounded by a sloping slab on grade with over 200 pedestals to be cast to an exact height to support the equipment which was placed above.

What obstacles were overcome related to the schedule, budget, program, specification, site, etc. on this project?

Due to strict timelines required for equipment deliveries, the project team had to coordinate the use of multiple casting bed pours to get the building lifted and closed in. The building contained multiple cast in place trenches and pits which required extensive coordination between the different trades to ensure project schedule was adhered to.

What is the potential for this project's impact on the community and/or environment?

This facility was built to create the first aluminum solo cups which are 100% recyclable and better for the environment.

Main banner image for TC Ball Cup Manufacturing Facility

Project Location

Rome, GA 30161
United States

Project Images


Project Team (TCA Members)

General Contractor:
Concrete Contractor:
Martin Concrete Construction Inc
Full-Tilt Constructors
PES Structural Engineers
Martin Concrete Construction Inc
Cari Gerrits
PES Structural Engineers

Project Specifics

Project Category:
Building Types:
Manufacturing Plant
Paint (Flat)
Post Applied (Interior)
Number of Floors:
Number of Panels:
97 panels
Tilt-Up Wall Area:
80,415 sq ft (7,471 sq m)
Total Floor Area:
240,000 sq ft (22,296 sq m)
Project Footprint:
240,000 sq ft (22,296 sq m)
Tallest Panel:
45 ft 5 in (13.84 m)
Widest Panel:
25 ft 6 in (7.77 m)
Largest Panel:
1,200 sq ft (111.5 sq m)
Heaviest Panel:
140,455 lbs (63,709 kg)
Longest Spandrel:
25 ft 5 in (7.75 m)