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Building with Tilt-Up | Project Profiles

Muscatatuck Urban Training Complex (MUTC) Subterranean Trainer

TCA Tilt-Up Project Profile - Special Projects Division

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Originally conceived as a pre-cast pipe tunnel system, the site contractor asked if a tunnel system could be constructed by the Tilt-Up method to achieve the earthen look and feel the U.S. Army wanted.

The panels were cast with a natural looking earthen surface, using the actual earth itself as a casting bed. As a result, when placed, the finished surface was already done. The floor made of earthen backfill was placed before the roof panels were installed; none of this would have been possible using precast pipe.

Headroom is consistent from wall to wall, although it varies in height depending on the section of the tunnel system. The structure consists of a maze of 1,111 lineal feet of tunnels with cross section areas of 6 feet by 6 feet, 4.5 feet by 4.5 feet and 3 feet by 3 feet. It also includes two "command" rooms." There are two main entrances that are exposed facing wooded areas and four access hatches, as well as lighting and a ventilation system. The structure is backfilled and covered 2 feet to 4 feet below the finished grade.

There is now a mock village above the tunnel system serving the dual purpose of hiding the tunnel's ventilation system vents and offering another training environment.


Project Specifics

Total Panels (Single Building)
205 panels
Project Wall Area
0 sq ft
(0 sq m)
Project Floor Area
59,617 sq ft
(5,538 sq m)
Project Footprint
100,758 sq ft
(9,360 sq m)
Tallest Panel
6 ft 6 in
(1.98 m)
Widest Panel
24 ft 3 in
(7.41 m)
Largest Panel
175 sq ft
(16.3 sq m)
Heaviest Panel
15,000 lbs
(6,804 kg)
Tallest Cantilever Panel
0 ft 0 in
(0.00 m)
Longest Spandrel Panel
13 ft 2 in
(4.03 m)

Participating TCA Members

Dayton Superior CorporationSustaining Member icon
Lifting hardware, Bracing
AML, Inc.Sustaining Member icon
General contractor

About the TCA

Founded in 1986, the Tilt-Up Concrete Association (TCA) strives to improve the quality and acceptance of site-cast Tilt-Up construction, a method in which concrete wall panels are cast on-site and tilted into place. Tilt-Up construction is one of the fastest growing industries in the United States, combining the advantages of reasonable cost with low maintenance, durability, speed of construction and minimal capital investment. At least 10,000 buildings, enclosing more than 650 million square feet, are constructed each year using this construction method.

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