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Building with Tilt-Up | Project Profiles

Saint Mary Coptic Orthodox Church

TCA Tilt-Up Project Profile - Spiritual Division

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Saint Mary Coptic Orthodox Church presents an old world theme using the adaptability and strength of tilt-up construction. The structure was originally designed as reinforced masonry with metal gauge framing, lath, and stucco at the facades. The tilt-up conversion features 95 panels plus a full dome, 29 feet 8 inches in diameter and with a weight of 101,900 pounds, cast and lifted as a panel.

The front facade contains the project's heaviest panel at 201,220 pounds. This panel rests on four substantial column/panel extensions between the towers, and a series of panels step down behind it to form a vault design. Behind the altar is a series of three panels, at a radius of 11 feet, to form a 180 degree backdrop. Two smaller 3-foot radius panels form a niche for a side chapel. The main dome rests on a solid 8-inch-thick by 6-foot-tall, 360 degree concrete wall that is supported by a 14-inch-thick roof panel, which was all poured on a casting bed and then erected. Two smaller half domes were cast in place on top of radius panels after the panels were erected.

The twin towers, which exceed 65 feet in height, were built with a series of panels. One tower serves as an elevator hoist way, while the other is utilized as an exit stairway for the mezzanine. Side slope roof panels serve as a tie between lower outer panels and upper spandrel panels that rest on steel beams with weld connections. Crane access was limited to one elevation.

Temporary casting beds were used for the majority of panels with the erection sequence critical in the layout of panels, as the building was constructed front-to-back. Center sections of slab on grade were left out so that the crane crawler could walk through and place panels safely.


Project Specifics

Total Panels (Single Building)
95 panels
Project Wall Area
31,201 sq ft
(2,899 sq m)
Project Floor Area
13,750 sq ft
(1,277 sq m)
Project Footprint
11,814 sq ft
(1,098 sq m)
Tallest Panel
44 ft 7 in
(13.59 m)
Widest Panel
38 ft 10 in
(11.85 m)
Largest Panel
1,022 sq ft
(94.9 sq m)
Heaviest Panel
201,220 lbs
(91,272 kg)
Tallest Cantilever Panel
31 ft 5 in
(9.58 m)
Longest Spandrel Panel
43 ft 1 in
(13.13 m)

Participating TCA Members

Houlihan Construction LLC
General contractor
Johnson Structural Group Inc
Project engineer
Meadow BurkeSustaining Member icon
Tilt-Up accessories
HD Supply Construction & Industrial White Cap
Tilt-Up accessories
Nox-Crete Products GroupSustaining Member icon
Tilt-Up accessories
Dayton Superior CorporationSustaining Member icon
Tilt-Up accessories

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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