INTRODUCTION OF TILT-UP STRUCTURES IN THE PHILIPPINES

Kenneth D. ODell1 and Jose Carlos A. Valencia II2

1

Vice-President/Partner of MHP Structural Engineers, Long Beach, CA, USA 2 Department Head, MHP Structural Engineers., Manila, Philippines

ABSTRACT: Traditional methods of construction in the Philippines rely heavily on the use of construction materials which need applied finishes. Common wall construction includes the use of CHBs faced with plastered finishes or exterior walls made up of structural steel columns with heavy gage metal studs covered with gage metal panels. In both of these traditional approaches, what is common is the aspect of time consumed in view of the multi-stepped processes that is required to be undertaken. Tilt-up construction is a method which eliminates the time consuming process of building wall assemblies which need finishes, as well as eliminating the cumbersome practice of constructing two wooden walls to get one concrete wall. It is the process of casting concrete walls flat on site and then lifting or tilting them into place. Great benefits can be derived from tilt-up structures such as economy, versatility, durability, and construction speed and design flexibility, among others. While tilt-up construction has a long history in the other countries, its use in the Philippines is a relatively new concept. Nonetheless, it is the authors opinion that tilt-up design can quickly become a method of choice for local construction of modern industrial and commercial building facilities such as warehouses, call centers, distribution centers, retail stores, commercial stores, as well as office and storage buildings. Likely all construction practices, tilt-up structures require preconstruction planning and design. In tilt-up construction this planning and design comprises the aesthetics such as building facades, coordination of wall panels in liftable units, sequencing and layout of the wall panel construction, and equipment access for lifting the panels; together with multiple engineering design decisions. The end result is a wall construction technique which provides complete wall assemblies that provide both vertical load support and a lateral load resisting system which often just needs painting to complete the architectural finish. To achieve the objective of this article as far as structural engineering is concerned, the design requirements and construction techniques for tilt-up structures will be discussed. Design issues to be addressed include seismic design (both in-plane shear and out-of-plane loading) of wall elements, connection of the wall panels to floor or roof diaphragms. Keywords: Tilt-up Construction; Tilt-up wall design; flexible/rigid diaphragm

1. MAIN BODY OF THE PAPER 1.1. Introduction Have you ever driven past a construction site and seen massive cranes lifting huge panels of concrete in the air? Have you watched with amazement as a new building seems to rise up into place, almost overnight? What you have witnessed is tilt-up concrete construction. Tilt-up is a construction method which eliminates the cumbersome practice of constructing two wooden/steel forms to get one concrete wall. It is the process of casting walls or other concrete elements on site then lifting and placing them into their final location. Early on in the history of tilt-up concrete construction , the concept was mainly confined to flat panels in commercial buildings where aesthetics was not of major importance, however, with more current projects, the use of tilt-up construction has run parallel with the developments in architectural designs. The system now offers designers a diversity of aesthetically pleasing structures at economic advantage compared to other building systems.

1.2. History The basic principle behind tilt-up construction of constructing walls horizontally, on the ground, and then lifting them into place is not a new idea. Evidence exists that some buildings constructed during the Roman Empire and the Middle Ages used this approach where they constructed the wood walls for their buildings and tipped them up into place. The development of reinforced concrete with rebar in the early 1900s allowed builders to create tilt-up commercial structures as we think of them today: One to two storey structures built with walls comparable in width to those other methods of construction. It is when the mobile crane was developed, that allowed builders far greater ability to lift the massive panels into place, regardless where the construction site happens to be. And about this time, ready-mix concrete was introduced to the industry, making tilt-up concrete an even more practical option.

Since then, tilt-up construction has undergone significant development and many refinements which enabled designers and contractors to derive greater capabilities and modernization in its use.

vital to any successful job and should be included in the deliberations and planning as early as possible. It is important that each member of the team is aware of the constraints of the method and of the broad implications of any planning decisions. Compromise will often be necessary; the participation of all the members of the team in all decision making is therefore required if the best solution is to be found, particularly for the casting and erection sequences. Changes should be made during construction only after careful consideration since many decisions depend on or affect other operations. Reversing one decision may start a chain reaction, which would necessitate the reconsideration of all subsequent decision. The benefits of the tilt-up method are optimised when the building is designed for tilt-up. Adapting a design based on the use of a different form of construction can be difficult and will often result in the tilt-up panels serving only as cladding, size being dictated by grids and frame spacing selected to suit other considerations. The following points should be considered at the early planning stage in order to exploit the benefits of tilt-up. Make use of as many of the panels characteristics as possible (structural, acoustic, thermal, fire resistance, etc.) Decide where access is to be provided onto site for concrete supply and cranes. Establish the broad approach to the casting and erection procedures. As the floor slab often acts as the casting surface and the erection platform, early access to site for casting of the slab becomes critical. Consideration of the positioning of the shrinkage control joints in the floor slab and the finishing which reflects in the forming of the tilt-up panels needs to be given. If the available room onsite is minimal stack casting will need to be considered. Other factors which are relevant at this stage are crane size availability which will determine the maximum panel size, special surface finish requirements, positioning of panel props and time available for casting and erection.

1.3. Aim of the Paper While the concept of tilt-up concrete construction is not a new method, this paper aims to introduce this construction method and show basic seismic design concepts for tilt-up structures. This paper also intends to show great benefits that we can derive from its applicability through a discussion of the advantages and, where appropriate, the disadvantages of tiltup construction.

1.4. Current practices Current major practices in the Philippines for the majority of one and two storey buildings including office buildings, retail centers, warehouses, distribution centers, call centers, manufacturing facilities, commercial structures, and industrial structures is still in the traditional form of vertical wall construction. For the majority of these building types the walls are built with concrete hollow blocks (CHB) with plaster on both faces. For most of the industrial buildings the exterior walls are made up of structural steel columns with heavy gage metal studs covered with metal gage panels.

1.5. Planning for Tilt-up The Planning phase of tilt-up project is one of the most crucial for its success. During this phase the entire design and construction procedure for the building should be worked out. Time spent in thorough planning can be repaid in full by a problem-free construction. At the planning stage the various alternatives for each aspect of the project can be calmly evaluated; once construction is underway, timely evaluation may not be possible since the speed of construction can become the overriding consideration. Two aspects of planning for tilt-up are worthy of particular mention; firstly, the need for the continuous involvement of every member of the design/construction team; secondly, the need to design the building specifically for the method. The cooperation of the whole team is necessary if the advantages and versatility of tilt-up are to be fully exploited and if cost benefits are to be maximized. It should begin at the planning stage and continue through the completion of the project. The team involves the architect, engineers and the contractor group. The contractors crane operation is

It is important to realise the scope of the project at this stage and a scale model of the building and site can be very useful.

1.5. Process of Tilt-up Construction A tilt up project begins with job site preparation and pouring the slab-on-grade. During this phase of the project, workers construct the wall footings around the slab in preparation for the panels.

The workers then assemble the panel forms on the slab. More often than not, the form is created with wooden pieces joined together and serves like as a mold for the panel. The form should be the panels exact size and shape with doorways and window openings included. Care must be taken to ensure the panels meet the design specification so they will fit together properly when lifted in to place. Next, workers tie in the steel reinforcements into the form. They install all the inserts and embeds for lifting the panels and attaching them to the footing, the roof system, and to each other. The slab beneath the forms is then cleaned of any debris or standing water, and workers pour concrete into the forms to create the panels. Now comes the point where tilt-up construction gets its name. Once the panels have cured, commonly to 75% of the design strength of the concrete, and the forms have been removed, the workers connect the first panel to a large crane with cables that hook into the inserts. The size of the crane depends on the height and weight of the panel. The crew also attaches the braces to the panel. The crane lifts, or tilts up the panel from the slab into vertical position above the footings. Workers help to guide the panel into position and the crane sets it in place. They connect the braces from the tilt-up panel to the slab, attach the panels embed to the footing, and disconnects the cables from the crane. The lifting crew then moves to the next panel and repeats this process. The crew should work as a team, setting the braces and guiding the panel with remarkable precision. With team and good coordination, the speed of process is very remarkable. Once all the panels are in place, erection of the roof system can be initiated while other crew members apply finishes to the concrete panels with sandblasting or painting, or whatever aesthetic requires. They also seal joints and patch any imperfections on the panels. In this way the construction schedule can be shortened since multiple tasks can occur at the same time. From this point the other trades can begin their work inside the building.

Savings in Construction Cost Tilt-up provides numerous construction cost saving opportunities. This system of construction uses locally available materials unlike structural steel which still needs to be imported. This means that raw material costs are lower, and materials are available when needed. Tilt-up work crews are typically smaller than the crews used in traditional construction. That translates to local labor. Because of economies of scale, the larger the footprint for the building, the more these savings improve the projects total cost. Fast Construction Schedule Tilt-up offers several opportunities to compress the schedule and deliver the building in a very reasonable time. Erecting the walls with tilt-up panels is faster then building walls using traditional construction methods. The trades can begin work earlier in the process on a tilt-up project, which allows greater overlapping of project phases. Because the building is made up (mostly) of ready-mix concrete from local sources, the project is less likely to be affected by transportation delays of materials unlike of structural steel that needs to be imported from outside the country. All these factors provide for a faster, more predictable schedule with fewer opportunities for delays and associated cost overruns. Safety The vast majority of the project takes place on the ground rather than on scaffolding , reducing many of these risks normally faced by workers. Aesthetics Tilt-up buildings are not prefabricated. Each one is custom-designed for the clients needs and preferences.

The benefits of a tilt-up project continue long after it is completed. Durability - in other countries where tilt-up have long been used, many structures created in the 1940s are still in operation today, with little apparent wear. A testament to the strength of tilt-up construction, owners, designers, contractors in earthquake-prone California now use this method for 90% of their one-storey industrial buildings. Fire Safety - The concrete used in the tilt-up panels meets the fire-resistance standards of even the most demanding building codes. Typically, a 162.5mm (6.5) concrete wall will have a fire resistance rating of four hours or more. Tilt-up panels can also be used in the buildings interior as fire separation walls. Tilt-up buildings offer real protection and safety for the tenants employees, property and ongoing operations.

1.6. Advantages & Disadvantages of tilt-up Construction Advantages: Tilt-up construction provides many numerous advantages over steel buildings or traditional CHB construction for warehouses, call centers, distribution centers, retail stores, office buildings, storage facilities and other types of industrial and commercial projects. Generally speaking, a 4,000 sq.m. building project is an excellent candidate for tilt-up construction.

Ease of Maintenance - Tilt-up buildings require little in the way of ongoing maintenance, outside of periodic cleaning and repainting as desired. Repairs and Expandability - In the event a wall is damaged by a forklift or truck, damage is typically localized on a panel than in other types of structures, like steel buildings. Also the modular design of the panels allows for easier repairs and future expansion of the building. Security Facilities that require positive security management of the interior environment prisons, business with clean rooms will appreciate the strength and control afforded by concrete tilt-up buildings. Reduces Insurance Premiums Because tilt-up buildings have superior resistance ratings and have been proven to withstand severe earthquakes, these buildings typically have better insurance rates than steel buildings or other type of structures. Reduced operating costs - Concrete provides excellent insulation, reducing the ongoing cooling costs for the tenants This insulation extends to sounds as well as temperature. Workers in a tilt-up office building located in a noisy area will be less affected by the environment. By the same grounds, a manufacturing business that generates noise will have less effect on its neighbors.

The same structural principles apply to the design of the tiltup panels as to normal cast in-place concrete construction. It is necessary , in their design, to satisfy a number of independent criteria. Wall panels must be designed for not only the loadings and conditions to be experienced in the final structure, but also for construction loads during erection. Design for lifting the panels is frequently the most critical design state and sometimes will dictate the design of the panel. Throughout the design phase there should be a conscious striving for buildability. A check of the design details should be carried out to ensure that they are practicable. The designer must also anticipate the construction practices and allow for realistic tolerances. 2.2. Construction loads 2.2.1. Lifting Probably the most severe loadings experienced by the panel will be that to which it is subjected during lifting. The design loading must allow for the self weight of the panel, the suction between the panel and the casting surface, and the dynamic loading which will occur when the panel is separated from the casting surface and as the panel is lifted by the crane. The effect of these forces must be considered firstly on the panel and secondly on the lifting inserts. For the typical panel, the reinforcement will normally be central in the panel section acting like shrinkage and temperature steel. This is different to normal concrete design, where the reinforcing steel situated near the outside face carries the tensile loads. 2.2.2. Bracing It is unusual for the temporary bracing condition to control the panel design. However, the brace loading needs to be determined so that the bracing and inserts can be check for adequacy to ensure the stability of the panels for the temporary condition prior to securing the roof diaphragm (figure 2.2.2a). It is recommended that bracing should be designed for wind loads. Loads to due wind are calculated per figure 2.2.2a. Note that the braces themselves may require lateral supports to prevent buckling under the full rated compression load. Two braces per panel should be used to provide stability against panel twisting. The braces should be fixed to the upper half of the panel and the optimum brace angle is 45 degrees with the normal range 45 60 degrees. Braces should be of one continuous length and design to take the axial loads with a factor of safety of 2.0.

Disadvantages of tilt-up: It can be dangerous. The fact that panels of many tonnes weight are lifted by crane means that quality control and safety measures must be very stringent. Partly because of safety issues many proprietary products are required for this type of construction (such as the temporary panel braces), so set up costs, typically for the general or concrete contractors can be quite substantial. Because of the previous points, tilt-up is not typically suitable for small one-off jobs. Tilt-up construction is a fully engineered system, and as such alterations and revision cannot be easily made on the fly. For example, changing the size or location of openings without express approval of engineer.

2. Basic Structural Design Concepts of Tilt-up Structures 2.1. General

Figure 2.3.1a Rigid Diaphragms Diaphragms that dont meet the flexible diaphragm criteria are considered rigid. Rigid diaphragm analysis includes torsional moments with accidental torsion. Loads to vertical lateral resisting elements are based on the rigidity of the elements. The distance between the center of mass and center of rigidity produces a torsional moment under seismic lateral loads.

Figure 2.3.1b A diaphragm consists of many components such as the chords, drags or collectors, and the metal decking acting as the as diaphragm web (Figure 2.3.3). Diaphragms transfer inertial forces through the collective action of the diaphragm components to the primary lateral resisting system. Figure 2.2.2a

2.3. Basic Seismic Design Concepts 2.3.1 Diaphragm System Diaphragm system depends on the type of diaphragm the structure has. Flexible Diaphragms A diaphragm is considered flexible when the computed maximum in-plane deflection of the diaphragm itself is more than 2 times the average drifts of the adjoining vertical elements of the lateral force system. Loads are transferred to lateral resisting elements based on tributary widths.

Figure 2.3.1c 2.3.2 Determination of Diaphragm Force Fpx. Seismic forces on floor and roof diaphragms are specified in section 208.8.2.8 for NSCP 2001. The following expression is used to determine the diaphragm force Fpx at level x.
n

Ft +

F
i=x
i

Fpx =
n

Wpx

(NSCP2001 eqn 208-20)

W
i= x

With upper and lower boundaries per section 208.8.2.8 that,

0.5CaIWpx Fpx 1.0CaIWpx

17.93 kN/m

Redundancy Factor of = 1.2 is not applied to the Eh loads due to Fpx (such as chord forces and diaphragm shear loads). 2.3.2. Tilt-up Panel Design Considerations Detailed discussion of the Tilt-up panel design is beyond the scope of this technical paper. However, seismic force calculation for a one storey wall panels is illustrated and typical design steps and considerations are also presented. The procedure for the design of tilt-up panels is a process of trial and error which is greatly reduced by experience. The following steps are usually involved in design of tilt-up panels. 1. Determination of panel geometry including the height, width, openings, and recesses or architectural reveals. Define applied loading conditions including the axial and out of plane lateral loads. Weights other than the panels selfweight that are attached to the panel shall be included when calculating for the lateral loads. Eccentricity of the axial loads must also be considered. Start with an assumed panel thickness. Minimum thicknesses should be lc/50 for single mat of reinforcement, or lc/65 for a double mat. Typically, select a thickness that is also the same with the width of wood panel forms that are readily available to eliminate the time wasted in trimming wood panel forms to its designed thickness. Select an initial reinforcement area and run the design for each load case. Adjust panel thickness or reinforcement until an optimum design is obtained to satisfy load conditions and code requirements. Check for service load deflections and adjust reinforcement or thickness as required.

An example is shown for the application of this formulas. This example shows the determination of the diaphragm force Fpx of NSCP 2001 Equation 208-20, for the design of the diaphragm of a single storey building.

2.

3.

Given: Zone 4 I = 1.0 Ca = 0.44 R = 4.5 = 1.2 Diaphragm weight = 1.0 kPa Wall weight = 4.4 kPa NSCP 2001 section 208.8.2.8, item 3, design seismic forces for flexible diaphragms providing lateral supports for walls or frames of masonry or concrete shall be determined using eqn. 208-20 based on the load determined in accordance with section 208.5.2 using a R value not exceeding 4. Wpx = Wt of Diaphragm + Wt of height of normal walls = 35(1.0) + 2(4)(4.4) = 65.2 kN/m Fpx = 2.5CaI Wpx R = 2.5(0.44)(1.0)(65.2) 4 (NSCP Equation 208-20)

4. 5.

6.

2.3.2.1 Openings on panels Effect of openings on panels for out of plane bending can be approximated by a simple one dimensional strip analysis that gives acceptable accuracy and economy for design. Where openings occur, the entire lateral and axial load (including selfweight) must be carried by the supporting legs or design strips on each side of the openings (Figure 2.3.2.1a.)

Figure 2.3.2.1a 2.3.2.2 Axial Loads Vertical loads from the roof or floor can frequently be assumed as a uniformly distributed line load. These are applied at some eccentricity to the centreline axis of the panel. A minimum load eccentricity of half the panel thickness is recommended and it is to be additive to the effect of lateral loads and it should not be used to reduce the bending moment caused by lateral loadings. Where loads are very large and are supported directly by the panel (such as girder point loads), the effective width of the design section should be limited as shown in figure 2.3.2.2a 2.3.2.3. Lateral Loads The effect of lateral loads on tilt-up panels is frequently the largest involvement in the total out-of-plane bending moment. Seismic loads, wind loads, soil pressures are usually applied to the panel as uniformly distributed lateral load. For the purpose of this discussion only seismic lateral loads are considered. The seismic lateral loads for the design of the individual panel are based on the NSCP 2001. These forces are greater than that required for the overall building and will commonly exceed wind pressures in high seismic areas. especially for thicker panels. For Out-of-Plane forces for wall panel design, under section 208.7.2 design lateral seismic forces can be determined using either a.) Eqn 208-18, or b.) Eqn. 208-19 with limits as follows: Figure 2.3.2.2a.

Fp = 4.0CaIpWp Fp = apCaIp Rp 1 + 3 hx hr Wp

(Eqn 208-18) (Eqn 208-19)

0.7CaIpWp Fp 4.0CaIpWp

This example illustrates the determination of the total design lateral seismic force on a tilt-up wall panel supported at tis base and at the roof diaphragm level.

Determine the out-of-plane seismic forces required for the design of the wall section shown. This is usually done for a representative one-unit width of wall length.

fp = 0.448(4.32) = 1.94 kN/m This force Fp is the total seismic load on the panel, For the design of the panel for out-of-plane forces, this must be expressed as a fistributed load fp. For parapet forces (unbraced): Ap = 2.5 Rp = 3.0 fp = 3.33CaIpWp (fp for parapet) = 3.33(0.44)(1.0)(4.32) = 6.33 kN/m

2.3.2.4 In-Plane Shear Forces from the roof or floor diaphragms that acts parallel to the plane of the wall panels induce shear stresses and overturning moments in the panels (see figure 2.3.2.4a). In high seismic areas, the in-plane shear requirements may control the wall panel thickness and reinforcing design. Design considerations for tilt-up panels subjected to inplane forces are: 1. 2. 3. 4. 5. 6. 7. Resistance to panel overturning; Resistance to sliding; Concrete Shear Resistance; Increased axial forces on portions of the panel; Load distribution to foundations; Frame action in panels with large openings; Seismic ductility.

Given: Zone 4 Ip = 1.0 (NSCP 2001 Table 208-1) Ca = 0.44 (NSCP 2001 Table 208-7) Ap = 1.0 (NSCP 2001 Table 208-12) Rp = 3.0 (NSCP 2001 Table 208-12) Panel Thickness = 180mm Wt of concrete = 24 kN/m3 Calculations: Commonly, NSCP eqn 208-19 is more advantages to use, thus: At roof level: hx=hr Fp = 1.33CaIpWp < 4.0CaIpWp Therefore Use Fp = 1.33CaIpWp At the base level: hx=0 Fp = 0.133CaIpWp < 0.7CaIpWp Therefore Use Fp = 0.7CaIpWp Average Fp = 1.02CaIpWp The force Fp is considered to be applied at the mid-height of the panel and it should be distributed between the base and the top. Fp = 1.02(0.44)(1.0)Wp = 0.448Wp For panel thickness of 180mm, weighs 4.32kPa For a one meter-strip width of panel length

Figure 2.3.2.4a

2.3.3. Connections for Tilt-up Panels Connection for tilt-up panels should be designed to resist forces equal to or greater than the maximum force imposed on the panel component. Anchorage of concrete must be in accordance with NSCP 2001 section 208.8.2.7 and section 208.8.2.7.1. We can categorize tilt-up panels into 3 types of connections: a. b. c. Cast-in-place connections; Welded embedded metals; and Post- installed anchors or drilled anchors.

considerably, depending on the configuration of the embeds (i.e. length of embedment, configuration of anchor).Steel plates with studs are suitable for shear and tension as long as the edge distances are complied. Refer to figure

2.3.3.1 Cast-in-place Connections Figure 2.3.3.1a shows the common types of cast-in-place connections used in tilt-up structures. This type of connection involves casting concrete around reinforcing bars projecting from the panel to attach into adjoining panel. These types of connection are very strong to a point it can used to distribute loads over a substantial length. Good ductility can be achieved when overlapping bars are confined with closed ties. However, these type of connection are rarely used because they are expensive than other type of connections. They can also cause some problems such as cracking which results from concrete shrinkage and too much restraint.

Figure 2.3.3.1a 2.3.3.2 Welded Embedded Metals Welded embedded metal is the type of connections commonly preferred by designers due to cost and construction flexibility. Strength and ductility may vary

Figure 2.3.3b

ACKNOWLEDGEMENT

This paper was conceived out of the authors interest in Tiltup structures inspired by MHP Inc. Structural Engineers tilt-up projects. Likewise, it is worth to mention that without the opportunity working with MHPs projects on the design of tilt-up structures this participation on this convention could not have been possible

REFERENCES

CCANZ TM #34. Tilt-up Technical Manual Association of Structural Engineers of the Philippines. Earthquake Design Manual 2003 , Vol. 1 American Concrete Institute. Tilt-up Construction Design for Tilt-up Panels. publication 551.XR Chukwuma Ekwueme, PhD. Masonry Chronicles. Winter 2005-06 Tilt-up News. Tilt-up Construction History. Tilt-up Construction News Articles. www.tiltupnews.com

Figure 2.3.3c 2.3.3.3. Post Installed Anchors or Drilled Anhors Expansion bolts and epoxy anchors are used extensively in tilt-up construction. These types of anchors have little ductility compared with cast-in-place anchors, making them not suitable for seismic forces. They can be use, but the design load capacity should be reduced. Use of this type of anchors should be restricted to supporting smaller loadings, loadings from canopies or for repairs. These type of anchors is usually used where cast-inplace anchor may have been omitted or misaligned. Expansion anchors can sometimes have problems with premature failure in thin panels, particularly where the edge distance is inadequate. Power driven fasteners or shot pins may be used for light architectural components or for connections of steel stud framing that are attached to the panel but design loads should be reduced due to comparative unreliability of these fasteners in concrete.

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