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Building with Tilt-Up | Project Profiles

Aldi Distribution - Rosenberg

TCA Tilt-Up Project Profile - Warehouse/Distribution Division

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While this 647,000+-square-foot building has an exorbitant amount of reveals for a warehouse, it is a single, massive 51-foot 6.5-inch radius (outside radius dimension) panel on this that makes this project interesting. This is a 230,900+ pound main entrance panel that follows a fixed radius, is recessed on multiple tiers and has thickened, turned up columns full height along each end. This panel was cast after the rest of the panels were erected so the radius had to be perfect in order to fit into the allocated opening. This panel alone was over $300,000. The main reason this panel was cast after all other panels were erected is because it was originally specified as multiple pre-cast panels that were going to be erected in pieces on site but at the last minute, the pre-caster decided he didn't want to take the risk of the radius and backed out.

The formwork was similar to building a ships hull. The formwork was built, braced and filled with dirt and graded to the rough radius. Next, both the inside and outside faces of the exact curvature of the radius were established and screed guides were set to keep the exact radius curve. Both the inside and outside radius had to be constantly maintained during forming, establishing the grade, placing the casting bed, placing the reinforcing and place/finishing the panel. If at any time one of these was off, the panel would not fit. The structural panel, formwork and erection sequence were all designed in house.


Project Specifics

Project Floor Area
650,000 sq ft
(60,385 sq m)
Tallest Panel
39 ft 1 in
(11.93 m)
Widest Panel
50 ft 11 in
(15.54 m)
Largest Panel
2,200 sq ft
(204.4 sq m)
Heaviest Panel
230,900 lbs
(104,734 kg)
Longest Spandrel Panel
29 ft 4 in
(8.94 m)

Participating TCA Members

Dayton Superior CorporationSustaining Member icon
Lifting hardware
Nox-Crete Products GroupSustaining Member icon
Form release
Construction Materials, Inc.Sustaining Member icon
Seretta Construction IncSustaining Member icon
Tilt-up contractor
Richard Adams Engineers and Consultants, Inc.
Project engineer
HD Supply Construction & Industrial White Cap
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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