2021 TCA Tilt-Up Achievement Award - Muskoka Bay Resort
The five-story building required a sixth story on each of its three staircases for roof access. In total, approximately 13.4 million pounds of concrete were used to create the floor and wall slabs, resulting in 381 pieces. The building’s panels totaled 111,928 square feet, with 51,769 square feet for the walls. And 60,159 square feet for the floors. The total height of the building, from the footing to the top of the walls, was 86’ 9”.
Due to the size of the project, the contractor will adjust some elements of its normal process. A typical tilt wall build involves installing panels that are the full height of the entire structure. However, in this case, that would’ve meant pouring and erecting panels that were nearly 87’ tall.
To overcome this, the team took a different approach. Wall panels were designed one floor height at a time. With the floor slabs also being designed as site-cast panels. This unique tweak to their method allowed the team to execute the build in the safest and most efficient way possible. And their willingness to make these adjustments spoke to the company’s flexibility and tilt-up construction expertise. This project also needed some major lifting power to handle the building’s walls and slabs.
Muskoka’s Largest Panel
The largest floor slab weighed 144,720 pounds and spanned 890.15 square feet. The biggest wall, located on the fifth story, weighed 123,500 pounds and set a company record as the widest wall installed at 60 feet, 10 inches. To manage the size of these panels and reach heights of 160 feet, the team used a Liebherr LG 1750 lattice boom crane with a maximum load capacity of 750 tons. Its power and reach made it the ideal choice for this project. Additionally, a 350-ton mobile crane moved the panels close enough for the LG 1750 to lift them into place, ensuring a seamless installation.
The Muskoka Bay Resort condominium project began in May 2018. Originally designed as a cast-in-place concrete building, it required a more efficient solution due to site challenges, budget constraints, and tight timelines. After evaluating their options, the owners determined that tilt-up construction was the better choice.
Tilt-up construction offers a more cost-effective, energy-efficient, and durable alternative to cast-in-place concrete. It also provides unmatched architectural versatility, allowing for aesthetically stunning buildings that serve a variety of purposes.
With these advantages, tilt-up quickly became the leading option for Muskoka Bay Resort. By the first week of March 2019, panel construction was underway. The foundation was completed by the end of April, followed by underground work and floor slabs in May. The team began erecting panels on June 3, finishing the last one by July 18. Initially considered an alternative, tilt-up construction ultimately proved to be the superior choice.
TILT-UP ACHIEVEMENT AWARD
The Tilt-Up Achievement Awards were established to honor projects that use site-cast tilt-up concrete. To introduce new building types, advance industry technology and provide unique solutions to building programs. Winning entries illustrate the variety, beauty, and flexibility of tilt-up construction.