Innovative Tilt-Up Construction at VGXI Headquarters by Hanbury
Hanbury’s design for the VGXI Headquarters and Biomanufacturing Facility in Conroe, Texas, redefines the possibilities of tilt up construction. Known for pushing the boundaries of conventional construction methods, Hanbury utilized this approach to create a dynamic and visually striking building that meets both functional and aesthetic goals. By experimenting with panel types, textures, and chamfered edges, the team leveraged light and shadow to enhance the façade, all while ensuring sustainability with locally sourced materials and modular flexibility for future expansions. The project stands as an innovative example of how prefabrication can merge creativity, efficiency, and environmental performance.
Photography by Keith Isaacs Photography and Hanbury, Published with bowerbird
Hanbury Design has a reputation for pushing the boundaries of traditional construction methods. How did your design approach for the VGXI Headquarters reflect the firm’s broader philosophy, and what were the key influences behind reimagining tilt-up construction for this project?
We saw the constraints of tilt-up construction, which typically results in pretty uninspiring architecture, as a design opportunity. Our first thought was how far can we push the panels? We reached out to local subs in the market to determine the criteria, panel widths, thickness, recess depth, window openings, etc. We wanted to determine where we could be creative and innovate within a tried and true construction method.
The VGXI facility features four distinct panel types, each with unique textures and projections. How did this panel iteration process evolve, and what role did the alternation of these panels play in breaking up the building’s mass and enhancing its visual appeal?
We wanted to bring as much natural light into the occupied spaces as possible. We were limited in how much glazing we could afford and strategically we wanted the openings to help break down the scale of the massive façade. We modeled several iterations and studied the quality of light and how far it penetrated the interior, so the study of both panel types and textures was really about light, shade and shadow, and how we could use these to create a dynamic building façade and interior spaces people want to be in.
Tilt up construction panels at VGXI create a dynamic interplay of light and shadow. Could you describe the design strategies and testing phases, particularly with chamfered edges, that helped achieve this effect?
We only had 2” of recess to play with before adding overall cost to the concrete panels due to the placement of the steel reinforcing within the panels. We created physical scaled models of the façade to see if the 2” chamfer would have any affect on the play of light and it did. Additionally, a change in texture, and as a result, a change in the way that light hits the panels we were able to create the illusion that the depth of the chamfer was greater than it was.
The use of mock-ups during the design phase allowed for experimentation with finishes and textures. What insights did you gain through the mock-up process, and how did it shape the final design of the tilt-up panels?
We built a lot of physical and digital models in the office to test out our ideas using different software and materials. We believe it is important to model at different scales and in different mediums to iterate ideas and arrive at the best solution
Sustainability was a key consideration for the VGXI project. How did the use of locally sourced materials, on-site panel casting, and strategic panel placement contribute to the building’s environmental performance, especially in Texas’s climate?
We were able to dry the building in quickly which was critical in the Texas heat by utilizing the tilt up concrete construction. Additionally, we took advantage of the flat Texas landscape of this region for optimal lay down space for the panels and as a result had little to no disturbance to the existing landscape and ecosystems.
The facility’s modular design allows for future expansion without disrupting current operations. How did you approach the integration of these forty-foot tall board-formed tilt-up panels to balance both aesthetic variety and functional flexibility for future growth?
We used the board formed texture in places that the end users would be up close and experience on the interior like the elevator vestibule at the entry. The board form texture is also used to mark the location of a future monumental stair as part of the phase 3 administration wing.
Concrete tilt up construction often conjures images of utilitarian industrial buildings. How did the design team at VGXI challenge this preconception, particularly with regard to incorporating large openings for daylight and views—features not typically associated with laboratory settings?
We located the program spaces that people occupied along the exterior to allow for the natural light from the large openings to penetrate deep into the interior of the building and we worked hard to maximize the efficiency of the panels but still provide an abundance of natural light to the occupants. A big goal of the client was to create a work environment that was not sterile, by connecting the occupants to the outdoors and creating work environments people actually want to be in.
Given the success of the VGXI facility, how do you see prefab and tilt-up construction methods evolving in the future, particularly in their ability to balance architectural creativity with efficiency and sustainability?
We are already seeing it in other markets and other materials like mass timber. We are currently working on a higher education project where we are prefabricating all of the major building components due to schedule and cost constraints, balloon framing 11’ wide panels 44’ tall anchored to mass produced CLT floors over prefabricated cold formed interior metal studs walls. Similar to VGXI, we see the constraints of the project as an opportunity to innovate and think creatively.
