The TJX Companies' 1.3 million square foot warehouse and distribution facility in rural Pennsylvania brought many challenges to Cutler Associates during its construction – none of which was choosing an insulation system. Cutler recommended the THERMOMASS Building Insulation System and tilt-up construction for this massive undertaking - the fifth largest tilt building ever constructed.

The TJ Maxx Warehouse features 130 loading docks, 300,000 square feet of mezzanine, fully adhered roofing and over three miles of super flat floors. One of the challenges this $35 million project faced on its way to completion was its location. Nestled in Pennsylvania’s Susquehanna Valley, one million cubic yards of rock were blasted from this densely wooded area to accomodate the facility.

Cutler knew that the only way that they could meet the owner’s time frame was by using tilt-up construction and THERMOMASS insulated panels. This worked because it allowed for speedy construction and the elimination of perimeter columns. Three hundred contractors working six day work weeks helped get this project finished in less than ten months – meeting the owner’s time frame.

On a typical day, 600 yards of concrete were poured for the super flat floor and 15 to 20 panels were cast. About 35 panels were erected per eight-hour shift.

Though many challenges were faced during the construction phase, one challenge that the new TJ Maxx facility won’t face is higher energy costs. THERMOMASS facilities are among the most energy efficient operating buildings around. Add to that durability and the ability to withstand most natural disasters and you have a building that will be around for years to come.