When it comes to modern construction, concrete panels are a reliable and cost-effective solution for creating strong, durable structures. There are two main ways to deliver them: tilt panels and precast panels. While both methods result in similar end products, the choice between them depends on your project’s unique requirements.

What are Tilt Panels?

• Formed on-site, in large casting beds, where concrete is poured onto forms, reinforced, and left to cure.
• A robotic layout system guides the setup process using digital shop drawings, ensuring precise measurements and reducing the need for manual marking.
• Once cured, the panels are lifted into position by crane and temporarily or permanetly fixed into place.
• With continued advances in technology and equipment, tilt panel construction is becoming faster, safer, and less labour-intensive.

What are Precast Panels?

• By contrast, precast panels are manufactured off-site in a factory.
• The relevant plans and shop drawings are sent to the supplier, who forms the panels in accordance with the design.
• Panels are then transported to site and lifted directly into place.  
• This approach eliminates the need for large casting areas, making it more attractive option for projects with space limitations or constrained site logistics.

Size of site: Tilt panels are formed and poured on-site, so you’ll need sufficient space for casting beds. Crane access and safe manoeuvring are also key considerations. For projects on expansive or open sites, this is usually straightforward. Precast panels are fabricated off-site and delivered ready to install. This is a major advantage for constrained or built-up locations where on-site casting areas aren’t practical.

Number of panels: For projects with a large number of panels or repetitive layouts (like warehouses, distribution centres or bulky goods retail), tilt construction can often be more cost-effective as larger single panels can be poured. However, for projects with fewer, more complex panels, precast generally provides greater efficiency and consistency.

Design complexity and finishes: Precast panels are ideal when a high level of detailing, non-uniform shop or surface finishes are required, as they’re cast in a controlled factory environment. Tilt panels can still deliver excellent finishes (especially with modern robotic layout systems) but intricate patterns, fluting or embedded features are often easier to achieve off-site.

Timeframes: Tilt and precast each offer time advantages, but at different points in the program. Tilt lets you begin panel work earlier in the sequence because everything happens on site, but the actual panels take time to cure in which you’re vulnerable to weather delays. Precast is manufactured off site, which usually means a longer lead time for design and production. However, once the panels arrive, installation on site is very fast and can significantly compress the on-site construction window.

Budget and transport considerations: Tilt can reduce transport costs and is often more economical on spacious sites. Precast can be more cost-effective where site access is tight or when local labour or weather constraints would otherwise impact on-site works.

With over seven hectares of available space, a project like CHIC is an obvious contender for a tilt panel solution. Even so, we undertook detailed analysis to confirm it was the best approach.  

A key driver in this assessment was controlling the panel sizing through design. We kept the heaviest panels under 40 tonnes so they could be safely handled by a 110-tonne crawler crane. Exceeding this weight threshold would have pushed us into a larger crane class, driving up hire costs, increasing subgrade preparation requirements and introducing additional logistical constraints.

Because we were engaged under an Early Contractor Involvement (ECI) model, we were able to carry out this assessment early and collaborate closely with our consultants to refine the design accordingly. This was particularly valuable in addressing the multi-level aspect of the building, where crane access and the positioning of Level 1 panels added complexity. At ground level, increasing the size of certain panels reduced the number of footings, props, deadmen and ancillary works required, ultimately lowering costs.

Myth Busted: Tilt panels are limited to single-level warehouses
CHIC demonstrates the opposite. With the right engineering and early coordination, the tilt method can be used efficiently across multi-level, architecturally varied structures.

The result is a robust two-level concrete structure of high finish comprising 132 tilt panels. The first stage of panels was installed over six days, starting at ground level. Once the suspended deck is complete in January, the remaining Level 1 panels will be erected, after which cladding, awnings and architectural finishes will complete the façade.

Myth Busted: Tilt panels don’t provide a quality finish
Whilst precast factories do provide a more controlled environment, tilt methods have evolved significantly. With robotic layout systems and precise casting beds, on-site tilt panels can still achieve a very high level of accuracy and finish.

Some projects make the decision for you — and St Mary’s Coptic Orthodox Church was one of them.

On a tight inner-city site, built to boundary and surrounded by neighbouring properties, the tilt panel method simply wasn’t an option for this community building. The limited access and lack of space ruled out the large casting and crane setup required for on-site panel work.

But even if the space had been available, the structure demanded a precast solution because of the detailed design. The façade features deep fluted concrete panels that create a striking corrugated appearance. This level of detail would be nearly impossible to achieve consistently with the tilt panel method.

Working closely with our architect, consultants and precast partner, we developed a suitable, tailored precast methodology that addressed both the architectural complexity and the logistical constraints of the site.

This integrated concrete structure combined footings, precast and in-situ elements, post-tensioned slabs and structural steel across two basement levels and three upper floors. We meticulously coordinated every element from early design development through to shop detailing and installation.

Given the restricted access, panel size and installation sequence were critical factors. We engineered each panel for safe lifting and installation within the confined boundary. Joint detailing required close collaboration between our structural and architectural consultants to maintain the design’s rhythm and precision.

Our team played a key role in reviewing shop drawings and coordinating the interface between trades, ensuring that windows, feature metalwork and secondary steel structures integrated seamlessly into the precast system. To manage lifting challenges, we engaged a structural engineer to develop lift plans and basement back-propping, allowing the crane to operate safely within the site limits without compromising surrounding infrastructure.

Whilst the process was demanding, the result is a highly distinct façade that defines the building’s visual identity. This project illustrates what is possible when architectural ambition meets construction expertise.

Myth Busted: Precast panels are always more expensive

While transport and craneage add costs, precast panels can actually deliver savings, especially on projects with limited space or tight timeframes. Off-site production reduces on-site labour requirements and the risk of weather delays.

The St Mary’s site is not an example of this, as tilt panels weren’t feasible due to the severe access constraints. However, there are other inner-city projects with better access and adequate laydown space where tilt panels have proven to be the more economical option.

Not every constrained site rules out tilt panels. In some cases, a carefully planned on-site casting approach can be the most practical and even the safest method. Our Hawthorne Deluxe Cinema Precinct project is a perfect example.

Located on a busy suburban shopping strip surrounded by homes, powerlines and narrow access points, the site presented multiple challenges. A precast method wasn’t feasible, the panels were simply too large to transport and lift safely into position, and the level of disruption required for off-site delivery and installation wouldn’t have aligned with council requirements.

Instead, our team designed and executed an on-site tilt panel methodology, forming and casting 11 structural panels that make up the cinema’s external walls. These panels were integrated with a double brick wall system and external cladding elements, forming a robust structure that complemented the heritage character of the surrounding streetscape.

The largest of the panels were up to 310mm thick and weighed over 50 tonnes, making the lift and positioning process highly technical. With limited manoeuvring space and sensitive neighbouring properties, safety and precision were critical. We engaged in detailed lift studies, developed custom crane outrigger footing designs, and carefully mapped out each stage of the lifting sequence to minimise risk and avoid clashes with underground services.

Challenging ground conditions added another layer of complexity. To ensure stability for the 300-tonne crane, we engineered a mass footing system capable of supporting its load without requiring the crane to be repositioned between lifts.

Despite the site’s constraints, the outcome was a seamlessly integrated structure that delivered the cinema’s acoustic, aesthetic and structural requirements. The project proved that, with the right expertise and early planning, tilt panels can be effective solution even on compact urban sites.

Myth Busted: Tilt panels are only suitable for large, open sites

While space is an important consideration, our Hawthorne project shows that smart design, precise engineering and careful lift planning can make tilt panels a viable (and even more efficient) solution for smaller, built-up sites where precast simply isn’t practical.