CAST-TILT Sandwich panel

The Next Generation in Insulated Concrete Buildings

  • Fastest and most versatile forming system for insulated tilt-up concrete panels.
  • Saves you money in labor, in materials, and in energy bills.
  • Laboratory and field tested. Meets requirements for all seismic zones, above and below grade.
  • Nationally recognized for its energy efficiency.
  • For use in commercial, industrial, and residential construction


Delivering Strength, Efficiency, and Economy

The GibBAR WALL CAST-TILT technology was developed to create a strong, lightweight, insulated panel using standard weight concrete. CAST-TILT sandwich panels are designed with a "strong side" to carry the loads of the structure. The other side of the wall is a 2-inch thick wythe, bonded to the structural wythe with a series of fiber ties. The space between these two wythes of concrete is the insulating core. These three layers combined together create the "insulated sandwich" panel. The lightweight design of our CAST-TILT panel reduces the weight of the panel while retaining the strength required for the structure. The heavy, structural wythe's (marketed by other companies) are not required in many applications. We offer an alternative that will meet the structural requirements and improve the energy efficiency without adding additional cost or wasting resources such as steel, concrete, and labor. CAST-TILT technology gives you greater advantages in the management of costly resources while delivering strength, efficiency, and economy to your project.

Lessons Learned

As much as 30% of the reinforcing steel used in traditional "solid panels" supplements the strength of the panel during the lifting of the panel. Following the panel erection, the "extra" steel may serve no valuable purpose. In someĀ applications, as much as 40% of the concrete in the panel offers limited structural, thermal, or acoustic value. Engineering has learned how to use the components of the sandwich panel more efficiently to benefit the builder and the building owner. The GibBAR WALL CAST-TILT technology helps you deliver the building in less time, at a lower cost, and with lasting long-term energy efficiency.

Build Insulated Panels Faster

Through study, research, testing, and real-world work, we have developed a technology that will rival all other sandwich panel configurations. The GibBAR WALL CAST-TILT panel is lighter, uses less reinforcing steel, can be designed for partial or fully composite action, requires up to 40% less concrete, retains sufficient strength for all seismic zones, uses less labor to construct, and can be used both above and below grade.

Maximum R-value

In 1990, the Department of Energy presented an Energy Innovation Award to INDUSTRIAL FOAM, the inventors of the GibBAR WALL technology, for its distinguished contribution to our nation's energy efficiency. All of our CAST-TILT wall systems have their roots in this award-winning technology.

By refining the use of concrete and steel and modifying the shape of the rigid insulation board an ingenious design was born. The patent maximizes the use of all wall components resulting in R-values that range between 12 and 50. These panel designs eliminate nearly all thermal bridging. A 25-foot high wall will typically have an R-value of 28-33 before including the benefits of thermal lag associated with the concrete mass of the interior wythe. The panel thickness is 11 inches.

Panel Connectors

We use the Dayton/Richmond P-24 Delta Tie to develop greater stiffness in the panel assembly. Using this tie, our CAST-TILT wall uses up to 75% fewer ties verses comparable systems: this is a great labor saver. The Delta Tie is a truss, fabricated entirely from continuous wound alkali-resistant fiberglass rovings and alkali-resistant epoxy vinyl ester resins. This design eliminates thermal bridges.