14 Questions to Ask a Commercial Concrete Contractor Before Hiring
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Tilt-up construction has become a popular solution for commercial building projects of all sizes, from warehouses and distribution centers to office parks and retail complexes.
Known for its speed, efficiency, and cost-effectiveness, the tilt-up method involves casting concrete wall panels horizontally on-site, then lifting them into position to form the building’s exterior shell.
Unlike traditional construction methods that rely heavily on masonry or prefabricated panels, tilt-up combines the benefits of in-place casting with the speed of panelized installation.
The result is a durable, customizable, and architecturally flexible structure built to last.
This article walks you through the tilt-up construction process, from the initial site preparation to the final structural integration.
Table of Contents
1. Site Preparation
2. Foundation and Floor Slab Construction
3. Panel Design and Layout
4. Formwork Assembly
5. Reinforcement and Hardware Installation
6. Concrete Placement
7. Panel Lifting and Erection
8. Structural Integration and Roof Ties
9. Finishing and Integration
The first step in any tilt-up construction project is preparing the site.
This begins with clearing the land of vegetation, debris, old structures, and any other obstructions.
Once the site is cleared, it must be graded to ensure proper drainage and create a level base for the foundation and slab.
Proper grading helps prevent future water issues and ensures that both the floor slab and lifting operations are safe and stable.
After grading, the soil is compacted to meet engineering specifications. Soil testing assesses the soil’s load-bearing capacity and moisture content.
These results guide decisions about slab thickness, reinforcement, and soil amendments or stabilization.
Compacted, well-tested soil is critical to preventing future settlement or structural failures.
Before any concrete is poured or panels are lifted, it’s essential to coordinate with local utility providers.
Underground water, gas, electric, and telecommunication lines must be located, flagged, and (if necessary) relocated.
This step prevents delays and ensures the safety of workers and equipment during construction, especially during panel lifting operations when space and movement are restricted.
Once the site is prepared, the construction of footings begins.
Footings are excavated to the depth specified by the structural engineer, typically below the frost line and per the soil’s bearing capacity.
Reinforcing steel is installed within the trenches before concrete is poured. Reinforced concrete is significantly stronger, and the footings will play a crucial role in supporting the entire building.
These footings also provide critical support for the tilt-up panels and serve as the base for anchoring them after they are erected.
Learn More: Construction Footings: A Complete Introduction
The next major component is the slab-on-grade, which serves a dual purpose: it is both the building’s finished floor and the casting surface for the concrete panels.
Because it must support heavy construction equipment and act as a flatbed for forming panels, the slab is built to exacting standards.
Vapor barriers, reinforcement, and perimeter insulation (where required) are installed before the concrete slab is poured.
Flatness and levelness are critical in tilt-up construction.
According to the TCA (Tilt-Up Concrete Association), the slab must meet high FF (floor flatness) and FL (floor levelness) numbers — typically FF 50 or higher — to ensure that the panels form correctly and can be lifted without damage.
The slab must also achieve a minimum compressive strength (usually around 3,000–4,000 psi) before it can be used as a casting bed.
This may take several days, depending on the concrete mix and environmental conditions.
Curing is essential to help the slab achieve its designed strength and durability.
Methods such as moisture-retaining blankets, continuous water misting, or curing compounds are applied to prevent rapid moisture loss.
Inadequate curing can result in surface cracking or strength deficiencies, compromising panel casting and future floor performance.
Keep Reading: How Our Concrete Curing Process Maximizes Compressive Strength
Now it’s time to design the tilt-up building to meet the project’s needs while maintaining proper concrete construction standards.
Before any physical layout begins, each tilt-up panel is designed and engineered to meet the building’s structural demands.
This includes calculating vertical and lateral loads, factoring in wind, seismic forces, and the weight of the panels themselves.
General contractors enlist the help of engineers to determine the thickness of the tilt-up concrete panels, the amount and type of reinforcement required, and the necessary lifting inserts.
In parallel with structural design, architectural teams finalize the layout and appearance of each panel.
This includes much more than just the building’s square feet. It involves the placement of:
The tilt-up method allows for great design flexibility; panels can be textured, colored, and even curved.
Once the slab has cured and been inspected, the layout crew uses full-scale drawings to mark the exact dimensions of each panel directly on the floor slab.
Using chalk lines, lasers, or total stations, they outline:
The chalk outlines serve as the template for constructing the panel forms in the next step.
When considering tilt-up methods, it’s useful to understand the differences between concrete and masonry for structural and design decisions.
The parts of formwork assembly include:
With the panel outlines chalked onto the slab, construction of the panel molds, or formwork, begins.
These molds are typically built from high-quality dimensional lumber, plywood, or reusable aluminum forms.
The edges are cut and fastened to match the exact dimensions of each panel, including openings for windows, doors, and utility penetrations.
Before any concrete is poured, a bond breaker is applied to the slab’s surface within the formwork area.
This chemical agent prevents the cast panel from adhering to the slab during curing. The bond breaker must be evenly sprayed or rolled on and allowed to dry thoroughly, ensuring clean panel separation at lift time.
After the perimeter forms are secured, crews place all block-outs, which are temporary inserts used to create openings for windows, doors, and utility penetrations.
These are often made from foam or wood and are custom-cut to match architectural drawings.
In addition, a variety of embedded items are installed:
These elements must be precisely positioned to align with structural and mechanical plans. Engineers typically verify their location before concrete placement.
If form liners will be used to add exterior texture, this is the time to do so.
Once the formwork is in place and cleaned, the structural reinforcements are installed within each panel mold.
The layout of rebar follows the engineering drawings and is critical for ensuring the panel’s strength during lifting, placement, and in-service loading.
Depending on the panel’s size, shape, and structural requirements, this may include:
In some designs, welded wire mesh is used as supplemental or primary reinforcement, especially in thinner or less complex panels.
Strategically located lifting inserts, typically made of steel, are embedded in the panel to enable the crane to safely pick and rotate the panel into a vertical position.
These inserts must be:
Additionally, bracing inserts or anchors are embedded to accept temporary braces that stabilize the panel after it is lifted, but before the roof or adjacent panels are connected.
Panels that include electrical systems, plumbing chases, or low-voltage wiring may require embedded conduit, junction boxes, or sleeves.
These elements must be installed with precision so they align with the building’s future mechanical and electrical layout.
Forms, hardware, and reinforcement are reviewed by project engineers and inspectors for code compliance.
The concrete pour begins once reinforcement and hardware have been inspected and approved.
Concrete is typically delivered by ready-mix trucks and placed into the horizontal panel forms using pump trucks or direct chute discharge.
Crews carefully distribute the concrete across the panel, ensuring complete coverage without disturbing embedded items or reinforcement.
Placement is done methodically to:
Crews often pour panels in a sequence that matches the crane lifting order to improve workflow and minimize curing delays.
As the concrete is poured, it must be vibrated and consolidated to eliminate air pockets (voids) and ensure it surrounds rebar, embeds, and complex block-outs.
This is typically done using internal mechanical vibrators, which are inserted into the wet concrete in a grid-like pattern.
Once finishing is complete, the panels must be moist-cured to allow the concrete to gain strength and durability.
Curing methods can include:
Most tilt-up panels must achieve a minimum compressive strength of 2,500–3,500 psi before they can be safely lifted, as specified in the project’s engineered lift plan.
This typically takes 3-7 days, depending on mix design, temperature, and humidity.
Once the panels have cured to the required strength, the site is prepared for lifting.
A mobile crane, sized appropriately for the panel weight and reach, is brought in and set up on firm, level ground. Before lifting starts, the lifting plan is reviewed and finalized according to details like:
Crane setup and operation must comply with OSHA and project-specific safety protocols.
With all safety checks complete, the crane slowly begins the lift. The panel is raised vertically off the casting slab and gently rotated into its upright position.
Often dramatic and highly choreographed, this process requires extreme care to avoid twisting, cracking, or collisions.
Once vertical, the panel is moved to its final position, with the interior walls followed by the exterior walls. Each panel is carefully aligned over anchor bolts or dowels and gently lowered into place.
Once placed, panels are secured with adjustable steel braces until the roof and floor systems lock them into a permanent position.
Panel erection is one of the most hazard-sensitive stages in tilt-up construction. Strict adherence to safety protocols is essential.
A single misstep during lifting can compromise structural integrity or result in serious injury. Planning, coordination, and oversight are non-negotiable.
With panels standing and temporarily braced, the next phase begins.
Installing the roof system involves erecting steel columns and beams, setting bar joists, girders, or trusses, and installing metal decking or concrete planks.
The roof system ties the walls together, distributing lateral loads like wind and seismic forces throughout the structure.
Coordination with the steel erection crew is essential at this stage to ensure sequencing aligns with panel placement.
The roof acts as a horizontal diaphragm, meaning it helps resist and redistribute horizontal forces across the building.
Once connected to the wall panels, the roof system enables the structure to behave as a single, cohesive unit.
Connecting the roof system to the wall panels with welded or bolted hardware completes the lateral load path.
After the roof structure is partially or fully installed, crews return to verify and adjust the alignment of each panel by:
Structural ties — like weld plates or tie rods — are installed to secure the panels at designated connection points.
Once the roof and necessary connections are in place and inspected, temporary bracing is systematically removed under the supervision of engineers to ensure safety and sequencing.
The final step in completing tilt-up projects involves a few finishing touches.
After all panels are in place and structurally tied together, the vertical and horizontal joints between panels are sealed to protect the building envelope.
Included in this process are:
Proper joint sealing prevents water intrusion, air leakage, and thermal bridging. It also improves the building’s acoustics, energy efficiency, and fire resistance.
Depending on the design intent, the exposed face of each panel may receive additional architectural finishes or coatings.
In many cases, the desired finish is already achieved during casting, particularly when form liners or integral colorants are used. Still, touch-ups may be required to correct blemishes or complete transitions.
As exterior work wraps up, attention shifts inward. Utility crews begin connecting the building’s embedded systems to active services.
Any embedded conduits installed during panel casting are tied into the building’s central systems, reducing the need for surface-mounted utilities and contributing to a clean, professional interior finish.
When executed correctly, tilt-up concrete delivers faster timelines, reduced material waste, and lower labor costs compared to precast concrete construction. This makes it a wise choice for both commercial developers and property owners.
With the right team in place, tilt-up is more than just an efficient building method; it’s a powerful tool for delivering high-quality commercial spaces that stand the test of time.
If you’re considering tilt-up construction for your next project, contact FMP Construction to discuss the possibilities.
