STANDARD

INDUSTRI
PEMBINAAN
(CONSTRUCTION INDUSTRY STANDARD)

CIS 9:20##
GUIDELINES ON HANDLING, TRANSPORTATION, STACKING AND
INSTALLATION OF PRECAST CONCRETE COMPONENTS

Descriptors: handling, transportation, stacking, installation, precast concrete, beams, columns,

slabs, walls, lifting inserts, minimum strength, rigging system, supports frames

© Copyright
CONSTRUCTION INDUSTRY DEVELOPMENT BOARD

Construction Industry
Development Board Malaysia
LEMBAGA PEMBANGUNAN INDUSTRI PEMBINAAN MALAYSIA
Ibu Pejabat CIDB,
Tingkat 10, Menara Dato’ Onn, Pusat Dagangan Dunia
No 45, Jalan Tun Ismail, 50480 Kuala Lumpur, Malaysia
Tel:603-40477000 Faks:603-40477020
https://www.cidb.gov.my
Guidelines on Handling, Transportation, Stacking and
Installation of Precast Concrete Components
CIS 9: #### Guidelines on Handling, Transportation, Stacking and Installation of Precast Concrete
Components

© Construction Industry Development Board Malaysia ####

All enquiries regarding this book should be forwarded to:

Chief Executive
Construction Industry Development Board Malaysia
Level 10, Menara Dato’ Onn,
Pusat Dagangan Dunia,
No 45, Jalan Tun Ismail,
50480 Kuala Lumpur,
Malaysia.

Tel : 603-4047 7000

Fax : 603-4047 7070
Email : standard@cidb.gov.my
Website : www.cidb.gov.my

No part of this publication may be reproduced or transmitted in any form or by any means, whether
mechanical or electronic including photocopying and recording without the written consent of CIDB.

Perpustakaan Negara Malaysia Cataloguing-in-Publication Data

 TABLE OF CONTENT
Committee representation v
PREFACE vi

SECTION 1 : GENERAL 1
1.1 Introduction 1
1.2 Objectives 1
1.3 Scope 1
1.4 Normative References 1
1.5 Definition 2
Precast components 2
Competent Person 2
Competent Installer 2
Lifting inserts 2
Embedment lengths 2
Dunnage 2
Corbel 3
Leveling shims 3
Sling length 3
1.6 Responsibility 3
Project Manager 3
Site Engineer 3
Site Supervisor 4
Construction Worker 4
Transport operator 4
Installer 4
Precaster / Manufacturer 4

SECTION 2 : HANDLING AND TRANSPORTATION OF PRECAST COMPONENTS 5

2.1 Planning for Transportation 5
Site Condition 5
Precast Element 5
Crane layout 6
2.2 Marking Labels 7
Definition. 7

i
 Marking requirement 7
2.3 Surface finishes 7
2.4 Handling 7
2.5 Minimum strength 8
Minimum strength for lifting 8
Minimum strength for handling 9
Minimum strength for transport and erection 9
2.6 Additional reinforcement for lifting and handling 10
2.7 Lifting 10
Type of lifting insert 10
Lifting Methodology 11
Units with no lifting inserts 12
Crane capacity and operating radius 13
2.8 Storage 13
Storage systems 14
Site storage 15
Stacking 17
Dunnage 18
2.9 Impact protection 19
2.10 Multiple handling 19
2.11 Support frames 20
2.12 Element protection 20
2.13 Delivery 21

SECTION 3 : ERECTION OF PRECAST COMPONENTS 24

3.1 General 24
3.2 Erection preparation 24
3.3 Planning cranage requirements 25
3.4 Rigging 26
3.5 Exclusion zone 29
3.6 Installation platform 29
3.7 Installation sequence 30
Installation of Vertical Precast Concrete Components 30
Installation of Horizontal Precast Concrete Components 31
3.8 Leveling shims 31

ii
3.9 Fixing inserts 32
3.10 Missing and unusable lifting points 32
3.11 Temporary bracing 33
3.12 Bracing insert 34
3.13 Temporary propping 36
Propping of beams 37
Propping of precast floor systems 37
Temporary supports for precast cladding 38

SECTION 4 : SAFETY IN SITE OPERATION 39

4.1 General 39
4.2 Working at Height 41
Reduction of work at heights 41
Limitation on work at Heights 41
Selection of access to Working Places 42
Vertical Movement on Steelwork 42
Horizontal Movement 43
Ladders 44
Work Platforms 45
Personnel Boxes 45
Fall Protection 46
Safety Harnesses and Anchorage Techniques 47
Personal Protective Method 48
Annex A 50
ACKNOWLEDGEMENTS 52

Figures

1 Marking of precast concrete components (Source: Creative Precast) 8

2 Lifting of single precast slab (Source: Creative Precast) 9
3 Lifting of multiple precast slab (Source: lhongtortai.com) 9
4 Lifting of precast beams (Source: Creative Precast) 12
5 Hoisting and rotating multistory units 13
6 Lifting of precast concrete column using lifting sling (Source: Creative Precast) 14
7 stacking of precast concrete wall panel horizontally (Source: Studylib.net) 17
8 wall panels stored vertically (Source: Cornish Concrete - Twitter) 17
9 Improper storage and stacking method (Source: Creative Precast) 19

iii
 10 Stacking of precast hollow core slabs (Source: Creative Precast) 19
11 Correct method of dunnage usage (source: Precast.org) 20
12 Temporary bracing of large openings (Source: BCA – Precast Delivery) 21
13 Protection method for transporting precast elements (Source: BCA – Precast 22
Delivery)
14 Transporting of precast concrete components on A-frame (Source: Creative 24
Precast)
15 Transporting of precast concrete components stacked horizontally (Source: 24
Safework with precast concrete New Zealand)
16 Crane lifting and rigging system 27
17 Lifting of precast U-drain (Source: Pintas Trading) 27
18 Examples of possible rigging configuration for lifting precast concrete elements 28
(Source: Safework with precast concrete New Zealand)
19 Rigging system 29
20 Rigging system 30
21 Lifting of precast element to its designated position (Source: Creative Precast) 32
22 Leveling shims (Source: Safework with precast concrete New Zealand) 33
23 Temporary bracing of precast column (Source: Creative Precast) 35
24 Correct method of placing inserts 36
25 Uneven erection loading 37
26 Worker walking on a beam 44
27 Worker straddling on a beam 45
28 Worker walking on bottom flange of an I - beam 45
29 Fall Arrestor 46
30 Hanging Work Platform 47
31 Steel Riggers Hook 49
32 Girder Grip Device 49

Table

1 Recommended minimum concrete strengths for lifting and handling 10

2 Floor Opening Protection 48

iv
Committee representation
The Technical Committee on IBS which supervised the development of this Construction Industry
Standard (CIS) was managed by the Construction Industry Development Board Malaysia and
comprises representatives from the following organizations:

Chicano IBS Engineering Design (M) SDN BHD

Construction Research Institute of Malaysia
Creative Precast Products SDN BHD
Eastern Pretech (Malaysia) SDN BHD
Green IBS Consult SDN BHD
Jabatan Kerja Raya (JKR)
Setia Precast SDN BHD
Universiti Teknologi Malaysia (UTM)
Universiti Teknologi MARA (UiTM)

v
PREFACE
The Guidelines on Handling, Transportation, Stacking and Installation of precast concrete component
is defined as a guideline of processes and controls necessary to help support best practice outcomes
for all stakeholders associated with the precast concrete component to be supplied and well deliver to
the sites. The aim of the guide is to coordinate and direct the stakeholders as best practices as whole
which may be considered and implemented the legislative requirements in each state for all parties to
understand their obligations.

In order to provide a balanced view on industry good practice, the document was prepared by expert
working group including representatives from various industry including engineers, precaster and
academia. It is intended for industry awareness and education and to drive positive change, which forms
a component of the Enforceable Undertaking.

In overall, this standard provides a practical guidance for the safe and efficient besides determining
procedures for proper handling, storage and protection requirements of materials, products and works
to prevent damage, accident especially the in preventing the inherently stable elements and impact
generated from the over loading during placement and removal on site. Besides, the establishment
framework of the standard system in ensuring the precast elements to be supply and deliver to the
project sites are handled orderly and was based on requirements of this Standard. This document scope
is focusing on the multi various projects including the residential, low-rise and multi-storey buildings or
structures.

The key process to Handling, Transportation, Stacking and Installation of precast concrete components
typically starts with:

1. Handling, transporting and storing the construction precast concrete components.

2. Best practices in ensuring the precast elements to be safely supplied and delivered to project
sites

3. A guideline for inspection based on existence of conformance to requirements used by

manufacturer and contractors.

With a well-structured practice, the overall handling, transporting, stacking and handling could focus
more on creating a safe and organised especially in organized the components without any damaged
which later may affect the structural integrity. The setting based on minimum specifications helps the
manufacturer and contractors to have the ease of use in using this document. Besides the best practice,
able to tracked problem matters, especially in providing the preventive measures on defects and
construction related issues prior to project completion.

As conclusion, this document able to ensure effectives of handling the precast concrete components
that reflect the technical and specifications conformance and full acceptance of the project.

vi
 GUIDELINES ON HANDLING, TRANSPORTATION, STACKING
AND INSTALLATION OF PRECAST CONCRETE
COMPONENTS

SECTION 1 : GENERAL

1.1 Introduction

The guidelines were upgraded and improvised based on the expert needs. This guideline covers the
proper method on how a precast concrete component should be handled until it is being transferred to
construction site. Methods for handling and storage of precast concrete elements will vary depending
on the type of element and whether the element is in the factory or on site. The important criteria are
safety of personnel and protection of the concrete element.

The handling and storage system must ensure safe transfer of the element from the mould to the
storage area and easy access to the element for removal and erection. At no time should a precast
element be placed in a position without positive restraint unless it is inherently stable. Inherently stable
elements are those elements that, due to their geometry, cannot tip or rotate when stored and subjected
to wind loads, construction loads and impact loads generated during placement and removal of the
element and, where appropriate, accidental impact from vehicles.

1.2 Objectives

The purposes of this standard are:

1. To provide practical guidance based on best practice for handling, transportation, installation
erection of precast concrete components in low-rise and multiple storey buildings.
2. To define procedures for safe and efficient handling, transportation, installation and erection to
prevent damage, deterioration or loss.
3. To establish a standard setting based on the minimum specification used by the designer,
manufacturers and contractors

1.3 Scope

This document contains useful information on method of handling, transporting and storing the precast
concrete components. This document comprises of 3 main parts. Section 2 contains all information on
the method of handling the precast concrete components on site from storing, lifting and transportation
of the precast concrete components from precast plants to the construction site. Section 3 presents a
detailed information on erection of precast concrete components which comprise all aspect from
preparation, bracing, equipment and etc. Section 4 discus on general information on safety and method
to manage the risk during planning and construction work.

1.4 Normative References

The Normative references clause lists, for information, those documents which are cited in the text in
such a way that some or all of their content constitutes requirements of the document.

1. Elliot, K.S, (2013), Multi-storey Precast Concrete Framed Structures 2nd Edition, Blackwell Science
Limited
2. Structural Precast Concrete Handbook (2001), Building and Construction Authority 2nd Edition
3. A. G. J. Way, Precast Concrete Floors In Steel Framed Buildings, The Steel Construction Institute

1
4. Standard Method of Detailing Structural Concrete 3rd Edition (2006), Institution of Structural
Engineers
5. Safe Work with Precast Concrete (2018), Worksafe New Zealand
6. PCI Design Handbook: Precast and Prestressed Concrete 7th Edition (2010), Precast/Prestressed
Concrete Institute
7. IBS Catalogue for Precast Concrete Building System (2017), CIDB Malaysia
8. Guide to managing risk in construction: Prefabricated Concrete (2019) Safe Work Australia
9. Best Practices on Occupational Safety and Health in Construction Industry 2019, Department of
Occupational Safety and Health, Johor
10. Garis Panduan Keselamatan dan Kesihatan Pekerjaan Industri Pembinaan (Pengurusan) 2020,
Kementerian Sumber Manusia
11. Guidelines For Public Safety and Health at Construction Sites (1st Revision), Department of
Occupational Safety and Health
12. Code of Practice for Precast Concrete Construction 2016, Hong Kong Building Department
13. Hoisting and Rigging Safety Manual (2020) Infrastructure Health and Safety Association (Canada)

1.5 Definition

Precast components

‘Precast Components’ are defined as structural precast components and are divided into seven main
categories, namely beam, column, half slab, hollow core slab, prestressed planks, staircase and wall
(load-bearing and non-load-bearing wall).

Competent Person

‘Competent Person’ is defined as any appointed Professional Engineer with Practicing Certificate
registered under subsection 10(D) of the Registration of Engineers (Amendment) Act 1967 (Revised
2015) from corporate bodies or consultant firm to provide professional services.

Competent Installer

‘Competent Installer’ is defined as a person who is expert in at least one precast component installation
and certified by Construction Industry Development Board (CIDB).

Lifting inserts

Lifting inserts are used for safe and efficient installation of concrete panels and are designed and
manufactured by specialists. They are cast into the concrete panel to aid lifting and installation by a
crane.

Embedment lengths

Embedment length is referred to as the distance the rebar is inserted into the concrete on a particular
placement. This amount of length is embed in another precast concrete member to ensure transfer of
stress among steel and concrete between adjacent precast concrete element

Dunnage

Dunnage is a material used to protect precast concrete material during storing and transporting.

2
 Corbel

Corbel is a very short structural cantilever member projecting from a wall or a column for the purpose
of carrying loads.

Leveling shims

Leveling shims are material used to level concrete during erection. Leveling shims will help even out
irregularities in foundation and other concrete structure during erection to keep everything level.

Sling length

Sling length is the minimum length of sling needed from the crane to hook to the sling’s connection or
contact point no the load.

Toolbox meeting

Toolbox meeting is an informal group discussion that focuses on a particular safety issue. Your team
can raise any concerns they have, as well as discuss incidents that have happened since the last talk.

Design review

A design review is a milestone within a product development process whereby a design is evaluated
against its requirements in order to verify the outcomes of previous activities and identify issues before
committing to - and if need to be re-prioritise - further work.

Shop Drawing

Shop drawing is a drawing or set of drawings produced by the contractor, supplier, manufacturer,
subcontractor, consultants, or fabricator.

1.6 Responsibility

This section on shows a typical roles and responsibilities as a guidance and is not compulsory to follow
as stated as different project will have different requirement on different work scope.

Project Manager

Project manager is responsible for overseeing the entirety of the project from start to finish. They may
individually manage a project, or work with other construction managers depending on the scale of the
project and its complexities. They are responsible for planning, budgeting, and overseeing progress.
During the planning process they must decide what materials to be used, how to schedule employees,
and create a schedule for the project. They must keep constant communication with all others on the
project as well as the client. They are on-call at all times because it is their responsibility if something
on the project goes wrong at any point. Due to the variety of job duties included in being a construction
manager, many find benefits in the implementation of cloud-based software to aid them in their planning,
implementation, and communication from start to finish.

Site Engineer

Engineers are very important on a jobsite. The site engineer should possess basic knowledge about
the practical construction procedures in site, along with the details of how they are planned. This idea
of planning and coordination will help him to have proper execution of the activities in the site with
desired performance. A site engineer is very essential for a construction project. The responsibilities of

3
a site engineer are wide as he must provide sufficient advice and supervision when there are any
technical issues, or for proper management and for the preparation of day to day reports of the
construction works. The site engineer is the one who have to ensure that the site have adequate
resources to complete the tasks. This is conducted by having procurement schedules for the jobs
carried out and liaise with the procurement department regarding the same.

Site Supervisor

The site supervisor acts as an intermediary between the field workers and the management office to
ensure effective communication. They are responsible for any problems or conflicts that may arise
between the field and the office. They have to ensure the construction sites follows safety regulation
and regularly inspect the construction site to identify and eliminate potential safety hazards.

Construction Worker

Construction workers are the driving force of every project. Once the project is planned, the workers
get their hands dirty to make it a reality. They demolish old structures and work to create new ones
following specific specifications. They must be able to operate heavy machinery, lift large objects, and
perform typical construction tasks. Aside from their physical requirements, they must be able to
effectively comprehend instructions they receive from their supervisors, and work collaboratively with
other team members.

Transport operator

A transport operator transports precast concrete elements from the production facility. The transport
operator may be part of the manufacturer’s organization, the customer organization, or a third-party
contractor. The transport operator shall be a fully competent person and with an active license. The
transport operator needs to ensure that the transport process follows the instruction from the shop
drawing and comply with the requirements from JPJ.

Installer

Precast concrete installer generally consists of a team of crane lifting supervisor, crane operator, signal
man and a competent labour. These team members responsible to ensure the components that arrive
on site are installed in proper order, as per construction drawings. All members of the installation team
must have been trained and certified before installation can be commenced.

Precaster

The roles of precaster is to manufacture the design made by design engineer. However under some
circumstances, precaster will take over the roles of designing of the structure such as design of hollow-
core flooring. Precaster has a duty to, so far as is reasonably practicable, make sure the precast
concrete elements they manufacture (e.g. pipes, beams or panels) are without health and safety risks.
Precaster shall discuss with the client, designer and head contractor on the requirement of the project.
Once a shop drawing has been made, it will need to have approval from the contractor or a competent
person before the concrete can be casted. Precaster are responsible to provide all the information
related to the elements based on calculation, analysis, testing or examination.

4
SECTION 2 : HANDLING AND TRANSPORTATION OF PRECAST
COMPONENTS

2.1 Planning for Transportation

Handling and transportation of precast concrete is one of the big aspects in precast components. This
operation needs to be planned as failure during transporting and handling precast concrete components
could involve the worker, transport operator, crane operator, pedestrian, road user and other worker in
the surrounding. This section consists of a consideration that should be taken when designing and
planning the precast components delivery, best practice on handling and delivery of precast
components.

Site Condition

Delivery of precast components to the job site required cooperation and coordination between the
fabricator, the transporter and the installer. Delivery planning shall be coordinated in such a way to
minimize double handling, which could risk damage to the precast concrete. In addition, site supervisor
needs to provide all weather access for the delivery vehicle to and around the site.

The transporter must ensure that the vehicle used is suitable to transport the elements and that the
elements are properly secured. A vehicle must not be moved without the load being secured in the
appropriate manner. The transporter must ensure that drivers have been adequately instructed in the
safe transportation of precast elements, with particular attention given to:

a) Power lines;

b) Recognized truck routes for over dimensional loads; and

c) Roundabout and reverse camber in the roads.

Differential road cambers may induce torsional loads in long precast components. Slender precast
components may require temporary stiffening against lateral buckling.

Before the shop drawings are prepared, element sizes and transportability should be reviewed to
confirm that the proposed elements are able to be transported to the building site and be erected. The
feasibility of transporting a crane of the required type and capacity to lift the elements also needs to be
taken into account.

Precast Element

The precaster must ensure that the concrete strength of the precast elements has reached the design
strength for transport and erection. Precast components must not be transported within three days of
casting unless the concrete used in the specific components is tested to confirm that the design strength
for erection has been attained. These test results must be available on site prior to erecting the element.

The size and weight of completed precast units may limit the design and these aspects need careful
design consideration. The length of a volumetric unit should not exceed 12m, the normal vehicle length.
The precast components’ height should not exceed 4.5m when loaded on the trailer; the components
could not enter the highway system if they exceed a height limitation ranging from 4.8 to 5.1m. The
precast concrete component should not exceed 7 tonnes to ensure that a crane can easily erect and
transport the material on-site.

The precaster must ensure that the elements are loaded in a sequence compatible with the required
unloading sequence on-site. Vehicles used to transport elements should be such that the center of

5
gravity of the load is as low as possible. Placement of the elements should evenly spread along the
vehicle's center line.

Where precast elements are carried on a flat top trailer, a safety chain must be placed around the front
edge of the elements to prevent forward movement. The rated safe capacity of a safety chain must be
at least half the weight of the load it is safeguarding.

Restraint equipment and anchor points must be strong enough to hold the load. The adequacy of a
particular method of restraint will depend on the type of element being transported and the type of
vehicle being used. The equipment must be inspected before use to ensure it is serviceable. Incorrectly
restrained precast concrete can move and risk to road user, worker and the concrete components itself.

Elements must be loaded so that identification marks are visible during unloading. The order of stacking
and the support details on the delivery vehicle and the design of the transport frames must permit the
precast components to be safely unloaded to temporary storage or be safely erected into the structure
in the required sequence. Adequate non-staining cushioning should be provided between the unit and
any securing chains, cables or ropes to prevent localized damage. Low friction material should not be
used as packing between concrete elements and supports.

Lifting points on the panels should be checked to ensure they are compatible with the lifting system
used. Lifting inserts should be clearly identified to assist in the loading and unloading stages

Drivers should stop and check the load and the restraints shortly after commencing the journey to
ensure that the load has not moved or settled. If movement or settlement is spotted, the load must be
re-secured and constrained before continue the journey.

Crane layout

It is important to decide on the type, size and number of cranes that are required to carry out the work,
since each has a designated range of positions relative to the work it is to perform. These positions are
then coordinated into an overall plan which enables each crane to work without interfering with its
neighbours, and at the same time enables each to work in a position where adequate support can safely
be provided. This plan will then form the basis of the erection method statement documentation. The
plan shall consider the routes for suspended loads, it needs to be arranged to ensure that no person is
required to work directly below a suspended load except for person engaged in the initial connection,
hooking or unhooking of the load.

A major factor in lift planning is to ensure that access is both available and adequate to enable the
necessary quantity and size of components to be moved. On large greenfield developments these
movements may often have to take place along common access roads used by all contractors and
along routes which may be subject to weight or size restrictions. On a tight urban site, the access may
be no more than a narrow one-way street subject to major traffic congestion.

6
2.2 Marking Labels

Definition.

Marking labels on precast components are important as it allows us to easily identify the precast
concrete unit’s detail. There is a couple of widely used labelling method in the industry which are
spraying, painting, barcode, sticker or QR code. These methods have its own advantage and
disadvantage however they serve the same purpose which is to identify the precast unit. Precaster
usually use a series of number or alphabet to label the precast components according to its database.
The database of the precast concrete elements shall contain every important information of each
precast unit. Mainly, the information includes the date of casting, cube test, unit load, reinforcement
configuration, installation location, manufacturer’s name and etc.

Marking requirement

Each unit should be clearly marked with a label that is durable, waterproof, and clearly visible for an
identification of the specific precast concrete components. Where the geometry of the unit does not
make it obvious, units shall have an orientation mark on the precast concrete. Figure 1 shows example
of marking on a precast concrete which include the identification of the concrete and the date of casting.

Figure 1 Marking of precast concrete components (Source: Creative Precast)

2.3 Surface finishes

Surface finish requirements will often dictate the preferred orientation of a precast element in the mould.
The quality of the finish of vertical mould faces may be inferior to that cast against a horizontal surface.
Two-stage casting is often used to avoid this problem.

2.4 Handling

Handling methods may vary depending on the facilities available and the types of elements being
manufactured. Elements may require multiple handling or rotation for processing or finishing.

7
The rigging system to be used and method of handling each element or type of element must be shown
on the approved shop drawings or set out in an appropriate work method statement. No element must
be lifted without the appropriate methods being documented. Figure 2 shows lifting of single precast
slab and Figure 3 shows lifting of multiple precast slab. It is to be noted that lifting of multiple precast
slab is only done during stacking or loading and unloading.

Figure 2 Lifting of single precast slab (Source: Creative Precast)

Figure 3 Lifting of multiple precast slab (Source: lhongtortai.com)

2.5 Minimum strength

Minimum strength for lifting

The minimum concrete strength at which precast elements can be lifted from the mould shall refer to
the engineer/designer’s specification. Table 1 discuss about recommendation of minimum strength
required before lifting of specific precast concrete element can be done. The following recommendation
may be used by the designer at the start of the design. The final value may be different from the value
in Table 1. The minimum concrete strength will be based on the calculated concrete stresses at the
lifting points or on calculated stresses caused by the transfer of pre-stressing forces or handling. Precast
element shall be stressed or lifted once the concrete achieved concrete grade at transfer subjected to
designer’s specification.

The minimum strength of the concrete at initial lift must be sufficient to develop the required capacity of
the lifting inserts. For vertically cast panels, or elements cast on tilting moulds the flexural stresses may
not determine minimum concrete strengths. The following table provides minimum concrete strengths
for lifting and handling.

8
Table 1 Recommended minimum concrete strengths for lifting and handling

Application Minimum concrete strength, 𝑓𝑓𝑐𝑐𝑐𝑐

None specified, fine controlled crane, 10 N/mm2 *
non-pre-stressed
Lifting which involves significant impact 15 N/mm2*
or high acceleration
All units here concrete strength for lifting As specified
is specified in the contract documents
Concentrically pre-stressed elements 20 N/mm2*
(piles, wall panels or thin floor slabs)
Eccentrically pre-stressed elements 25 N/mm2*
(Tees, deep flooring units)
Bridge beams and similar highly 30 N/mm2* or as specified
stressed pre-stressed elements
* Dependent on anchor length or as recommended by insert manufacturer
Note: Special care should be taken with pre-stressed elements to ensure lifting devices
are anchored in compression zones, unless covered by specific design.

Note: This value is only a general guide, manufacturer and installer should always refer to
the designer and the requirement for a specifc value of minimum concrete strength before
lifting operation can be commenced

Higher strengths may be required to develop the capacity of some lifting inserts or for safe handling of
the elements. It is to be noted that the capacity of the lifting inserts may be less than their rated capacity
due to short embedment lengths and/or low concrete strengths at the time of lifting.

Minimum strength for handling

The required concrete strength at 28 days will be stated in the contract specifications. This will be based
on strength or durability requirements as determined by the designer.

Precast concrete elements must not be removed from the moulds and placed in storage until the
concrete strength has attained the minimum value required for lifting as specified on the approved shop
drawings.

Concrete of a higher strength may be used for some precast components to enable early removal from
moulds or to enable construction loads to be carried at an early age. The expected 28-day strength of
this concrete must be noted on the approved shop drawings as over strength precast concrete beams
may alter the performance of concrete columns under earthquake loads.

Minimum strength for transport and erection

Transporting and erection will generally impose less stress on precast elements than those caused
during lifting from the mould. This may not be the case for panels cast in vertical or tilting moulds. In the
case of elements subjected to high stresses due to support conditions on trucks, or elements required
to carry significant construction loads, the minimum strength required for transport and erection should
be clearly stated on the approved shop drawings, and on the precast layout drawing. This would
normally be the responsibility of the design engineer of the element.

Precaster should be aware that allowing the concrete to dry out or prolonged cold weather can slow the
strength gain of concrete. The installer should ask for confirmation of concrete strength from match cast
concrete test cylinders, impact hammer tests, or other means.

9
2.6 Additional reinforcement for lifting and handling

The grade of reinforcing steel should be clearly noted on the approved shop drawings. Mixed grades
should be avoided if possible or, unavoidable, they should be clearly highlighted.

The precaster may decide to provide additional reinforcement to improve safety during transport and
handling. Examples may be top reinforcing bars in precast half beams, or crack central steel at transport
support points and lifting points.

The number of additional reinforcing bars should be calculated in accordance with sound design
principles and these should be clearly shown on the approved shop drawings. Details of additional
reinforcing should be submitted to the competent person for checking and approval.

2.7 Lifting

Before lifting operation, approved lifting instruction or shop drawing should be obtained by lifting team.
The approved lifting instruction should contain all information required for lifting operation which
includes but not limited to the minimum concrete strength for lifting, lifting point, weight of the unit and
angle of lifting. Design engineer or precaster needs to be consult if any discrepancy was found in the
shop drawing or lifting operation cannot be done as stated in the lifting instruction.

Lifting of precast concrete require special equipment, planning and coordination between multiple
individual. Competent individual needs to ensure the lifting process is done correctly to reduce
possibilities of failure. Lifting failure which may involve failure of lifting insert or lifting rig could lead to
devastating effect to the product, worker and other things surrounding the area. This section will focus
on the best practice for lifting of precast concrete elements.

Type of lifting insert

The type of lifting eyes or inserts to be used on a project should be mutually agreed between the
precaster and the contractor or installer. When designing lifting insert, the designers need to consider
the number of the lifting anchor, location of lifting anchor, position of lifting anchor, reduction of anchor
capacity when placed near an edge or an opening, component reinforcement, adequate cover to all
cast-in inserts, ductile behavior and robustness of the anchor and concrete strength required to reach
the required anchor capacity.

The size and number of lifting insert should be depends on lifting anchor capacity, total weight of
element, length and height of element, position of openings in the element, rigging arrangement,
possible influence of suction and friction during demoulding, influence of dynamic factors when lifting
on-site.

Lifting must not be continued if lifting parts are damaged or rotten, lifting points are different from the
specification, lifting inserts are different from those listed on the engineers drawing and the precast
components does not complies with the engineer’s drawing. Lifting process must always follow the
method statement written by the contractor. If the lifting operation cannot be done according to the
method statement or lifting parts are found damaged, the main contractor shall consult the design
engineer to ensure accident could be avoided. Figure 4 shows lifting of precast beams without using
spreader beam.

10
 Figure 4 Lifting of precast beams (Source: Creative Precast)

Lifting Methodology

The precaster must clearly identify elements requiring a non-standard lift.

a) Standard lift

A lift that does not require special rigging or equalization procedures i.e. no more than two anchors
must be capable of carrying the load with the required safety factor.

b) Non-Standard

A lift that does require special rigging or equalization procedures. This must be noted on the approved
shop drawings. Precast components such as multistory components may be stored and shipped on
their long side and handled at the jobsite by rotating in the air as shown in Figure 5. The suggestions
list was based on best practices.

11
 Figure 5 Hoisting and rotating multistory units

Units with no lifting inserts

Some precast elements may have no lifting inserts. These units must be handled by means of lifting
clamps designed by a suitably qualified person, or by lifting straps or slings. Lifting equipment of this
type wears rapidly, and must be regularly inspected by a suitably qualified person. Inspections must be
recorded.

On construction sites, elements handled by means of lifting clamps or forks should have the load
secured by safety slings or other securing devices. The location of lifting points should be indicated by
the designer or other competent person. Figure 6 shows lifting of precast concrete column using lifting
sling.

12
 Figure 6 Lifting of precast concrete column using lifting sling (Source: Creative Precast)

Crane capacity and operating radius

Every individual item of lifting equipment should be clearly marked with its working load limit (WLL), the
manufacturer’s identifier, and a unique numbering system. This allows the item to be easily identified
after the lifting anchors are cast into the precast concrete element.

The rated capacity or working load limit (WLL) of a crane refers to its maximum load capacity at the
minimum radius. This must not be confused with its actual capacity at working radius when lifting.

The required crane capacity is affected by factors including the distance from the center of rotation of the
crane to the center of gravity of the precast element being lifted. The rated capacity of a crane decreases
as distance of lift from the center of rotation of the crane increases. The operating radius for tower cranes
and large mobile cranes will generally be much greater, and a methodology should be developed between
the main contractor, crane owner and handling and erection personnel

Where lifting is not possible with one crane and it is necessary to use two cranes to "dual lift" elements,
the required crane capacities should be carefully assessed. The capacity of either crane must not be less
than 75% of the mass of the element

Precast elements are usually lifted at extended radii and this will usually determine the required crane
capacity. Crane charts should be referred to for the correct selection of cranes.

2.8 Storage

The storage area must be large enough for elements to be stored properly with adequate room for lifting
equipment and for maneuvering trucks and cranes. The area must be reasonably level and hard
surfaced with adequate drainage to ensure that a safe workplace can be maintained.

13
Elements must not be stored directly on the ground. Generally, two discrete support points must be
provided unless specifically approved otherwise by the project design engineer. Timber supports raised
above the ground or dedicated racking systems must be used in all cases. Elements should be stored
in such a manner that each element supports only its own weight without any load being imposed by
other elements. Where elements are stacked horizontally on top of each other, the following must apply:

Points of contact between elements and supports must be provided with protective material to prevent
breakage and staining. Special consideration must be given to pre-stressed elements to ensure they
are only supported at designated bearing points. Pre-stressed elements must not be supported, even
temporarily, at any other points.

Storage systems

Storage systems for elements that are not inherently stable must be designed to resist the loads and
forces applied to them. This includes wind loads, construction loads and impact loads generated during
placement of the element and, where appropriate, accidental impact from vehicles. The design of the
storage system must be fully documented.

To minimize the effects of vehicle and other uncontrolled impact, the element support systems (racks
and frames etc.) must be robust and designed so that failure at one point does not result in progressive
failure. Racking systems must be designed so that if one element falls it does not create a domino
effect.

Racking systems for vertically stored wall panels must be designed and constructed as follows:

a) At least two restraint points must be provided so that the panel is stable under the loads as note
above. The top restraint must be above the mid-height or center of gravity of the panel;

b) The restraint system must be designed to withstand the loads as noted above as well as loads
generated when the panel is up to 5 degrees off vertical; and

c) Where necessary provision must be made in the design of the restraint system for panels with corbels
and nibs.

Racking systems frames and supports must be constructed in accordance with a design prepared by a
qualified engineer suitably experienced in the field of precast concrete construction.

Frames, either single sided, or double sided 'A’ frames used to store wall panels must be designed and
constructed so that:

a) The frame and its supports remain stable and withstand the forces as noted above,

b) Panels remain stable in the frame when the panels are not restrained. The slope of the panels must
be such that the panel will not tip out of the frame; and

c) The frame and its supports accommodate uneven loading of panels. The limitations for uneven
loading must be clearly shown on the frame

Rack lifting points should also be rated and certified by a competent person. People loading the rack
should have quick access to this certificate and rating. Workers loading the rack should be able to see,
or quickly access, the certificate and rating. The certificate should show:

a) The loading and configuration used as the basis for design

b) Maximum load capacity/rating – and any restrictions

14
c) Maximum size and weight of individual precast concrete elements that can be stored

d) Whether work can be done on the elements while in the racks

e) Limits on ground slope, if relevant

f) Required ground strength, if relevant.

Site storage

Generally the sequence of erection should be such that storage and multiple handling of elements on
site are minimized or avoided if possible. Storage areas must be large enough so that precast units can
be stored safely, with adequate room for lifting

The required work method must be clearly document.

The general requirements for handling and storage of elements on site are as follows:

a) Elements must only be stored in a position approved by the project design engineer;

b) Ground conditions must be checked to ensure that the mass of the element can be supported and
the ground needs to be well drained to avoid any differential ground settlements which may damage
the stored component;

c) Where an element is to be stored on a suspended floor slab, approval and written instructions must
be obtained from the project design engineer before proceeding;

d) Wall panels may be stored in a suitable 'A-frame' or stood and braced in a vertical position. Bracing
should be in accordance with the general requirements of this code; and

e) Wall panels may only be stared horizontally in accordance with a written instruction from the erection
design engineer or project design engineer

Supports must be arranged to avoid twisting or distorting of the precast elements and must be adequate
to transfer the weight of the stacked units to the ground without excessive settlement.

Wall panels should preferably be stored in the vertical position. Where edge-lifted panels are stored
horizontally, they must be placed to ensure that component reinforcement around edge lifting inserts is
correctly orientated for re-lifting. Precast units must be stored safely with adequate supports such that
it would not endanger any workers moving in the vicinity. Figure 7 and Figure 8 shows storing of precast
concrete wall panel in horizontal and vertical position, respectively.

15
 Figure 7 stacking of precast concrete wall panel horizontally (Source: Studylib.net)

Figure 8 wall panels stored vertically (Source: Cornish Concrete - Twitter)

If a rack and frames are used to store the precast concrete, the person constructing the racks and
frames should be a competent person. They should check that racks and frames will remain stable
when precast concrete elements are placed on them.

Workers loading the rack should be able to see, or quickly access, the certificate and rating. The
certificate should show:

a) The loading and configuration used as the basis for design

b) Maximum load capacity/rating – and any restrictions

c) Maximum size and weight of individual precast concrete elements that can be stored

d) Whether work can be done on the elements while in the racks

e) Limits on ground slope, if relevant

f) Required ground strength, if relevant.

Some racks used for on-site storage can also be put on the back of trucks. If so, this should be specified
within the transport requirements. Note that A-frames designed to hold precast concrete panels in a
yard in a static environment have totally different loading stresses applied to them when used for

16
transportation. Rack lifting points should also be rated and certified by a competent person. People
loading the rack should have quick access to this certificate and rating.

Stacking

Incorrect stacking and storage can damage precast elements (refer Figure 9). For those units where
support points are critical, for stacking, transport or long term storage, the locations for dunnage or
support should be noted on the approved shop drawings or on the precast layout drawing.

Site supervisor must ensure the following:

a) The materials stacking height shall follow the method statement. If height of stacking is not available,
the stacking height shall not be more than five feet.

b) The element stored on a platforms or in building does not exceed its safe floor-loading specification

c) Allow sufficient clearance around stacks for safe handling and easy access

d) Ensure the stacks of precast elements don’t block emergency exits, emergency equipment or fire
alarms

e) Stack height must not be higher than twice the element width unless specifically approved otherwise
by the project design engineer and provisions are made to minimize the likelihood of accidental impact
from vehicles or other elements

f) Support points must be directly above each other unless specifically approved otherwise by the
project design engineer

g) The stacked height of elements must be limited to ensure that the ground bearers and lowest
elements can support the loads from above and that the stack remains stable

h) They must not be tipped sideways or stored directly on the ground.

Figure 10 shows stacking of hollow-core slab in manufacturer’s plant.

Figure 9 Improper storage and stacking method (Source: Creative Precast)

17
 Figure 10 Stacking of precast hollow core slabs (Source: Creative Precast)

Dunnage

Dunnage performs the important function of supporting the bottom unit of a stack clear of the ground,
allowing access between units to fit lifting forks or straps, and preventing damage resulting from
concrete-to-concrete contact as shown in Figure 11. Location for dunnage or support should be noted
on the shop drawings or on the precast layout drawing.

Figure 11 Correct method of dunnage usage (source: Precast.org)

The bottom level of dunnage must be adequate to transfer the load to the ground without excess
settlement. Settlement of dunnage can result in cracking of some types of elements.

18
Dunnage must be arranged to avoid twisting or distorting the precast elements. Dunnage for the next
level in a stockpile should be directly over the dunnage below. Materials used for dunnage on surfaces
that will be exposed in the finished structure should be non-staining.

Note: Variations in concrete curing under dunnage may result in colour variation that could take some time to fade.

2.9 Impact protection

For precast concrete elements stored in areas of vehicular movement, additional protection may be
required. This could include the use of bollards or other physical barriers. During handling and storage,
care must be taken to minimize the likelihood of impact between elements.

For elements with large openings, the temporary bracing, ties or strongbacks should be provided for
safe handling. Figure 12 shows the best practice use in the industry to transport a precast element with
a large openings. The main contractor shall refer the shop drawing or design engineer for the details of
the temporary bracing.

Figure 12 Temporary bracing of large openings (Source: BCA – Precast Delivery)

2.10 Multiple handling

The sequence of erection should be such that the multiple handling of elements is minimized. A specific
procedure should be developed and the operation supervised by a competent person if multiple
handling is required.

Elements should only be stored in a manner approved by the designer or other competent person.

19
2.11 Support frames

Frames used to support elements during transport must be designed to withstand loads and forces cling
on the system during loading, transportation and unloading.

A frame system that is not an integral part of the trailer must be separately and individually secured.
The fixing method must be capable of withstanding any forces applied during loading, transportation
and unloading.

Particular care must be taken during loading and unloading elements from frames to ensure that the
frames remain stable at all stages. Semi-trailers should be stabilized by lowering the support legs onto
a firm base.

Where unloading cannot take place on a firm level surface, elements must he individually restrained
and the loading configuration must be checked to ensure that removing individual elements does not
result in instability of the load or the vehicle. Restraints must not be removed until the crane takes the
initial weight of the element.

2.12 Element protection

Points of contact between elements, supports and restraints must be provided with protective material
to prevent breakage and staining. Corner protectors must be used under all restraints to prevent
movement and damage to the element. Figure 13 shows method that has been used by the industries
to protect the precast concrete element from damages during transportation.

20
 Figure 13 Protection method for transporting precast elements (Source: BCA – Precast Delivery)

Where elements are transported horizontally, they must be stacked so that each element can support
the loads from above. The support points must be directly above each other unless specifically designed
otherwise.

The stacked height of elements must be limited to ensure that the bearers and lowest elements can
support the loads from above and that the stack remains stable during transportation.

Special attention must be given to pre-stressed elements to ensure that they are only supported at
designated bearing points and that restraint systems do not impose excessive loads. Pre-stressed
elements must not be supported, even temporarily, at any other points and they must not be tipped
sideways.

2.13 Delivery

Delivery of the precast elements onto the site requires cooperation between the main contractor, the
transporter and the installer.

21
 Loading and unloading sequence should be planned before execution. Ensure that a confirmed
exclusion zone has been establish. The loading area should be on a firm level ground to prevent tipping
over. When loading the precast components, ensure that the identification marks are visible before and
during unloading, unloading can be carried out in the proper sequence, weight is evenly distributed,
vehicle is not overloaded, precast component is properly secured and each element in a multiple-
element is individually secured.

The precaster must ensure that the transporter has detailed instruction on how to enter the site. The
transporter must inspect the site prior to entry to verify that there are no dangers such as backfilled
excavations or overhead services. The area to receive the delivery vehicle should be firm and level.

The transporter must position the vehicle as directed by the installer and stabilized the vehicle prior to
releasing the element restraints. Semi-trailers should be stabilized by lowering the support legs onto a
firm base. The transporter must be aware of which elements are to be unloaded first. Figure 14 and
Figure 15 shows different method of loading the precast concrete elements on the transporter which is
horizontally or on an A-frame. The stacking method of the precast concrete on the transporter shall be
noted on the shop drawing.

If the unloading sequence can lead to instability of loads, the precast elements must be individually
secured. Individual elements must not be released until the crane has taken the initial load of that
element.

The transporter and the installer need to ensure the following:

a) Ensure that precast components total weight loaded on the trailer shall not be more than 7 tonnes
b) The vehicle must remain chocked and park brake is fully applied during unloading process
c) The load is secured in the appropriate manner at all times, including during the unloading operation
d) Check the lifting anchor for any damage and make sure it is as specified in the approved shop drawing
e) Individual precast concrete elements remain restrained during unloading until the crane has taken the
initial load of that element
f) A- frame should remain restrained until their weight can safely be taken by the crane
g) Record and report any damage found on the precast concrete elements before offloading the precast
concrete elements.
h) Consider escorted transportation of precast elements exceed the limit mentioned in 2.1.2

22
 Figure 14 Transporting of precast concrete components on A-frame (Source: Creative Precast)

Figure 15 Transporting of precast concrete components stacked horizontally (Source: Safework with
precast concrete New Zealand)

23
SECTION 3 : ERECTION OF PRECAST COMPONENTS

3.1 General

Safe erection of precast concrete elements depends on the pre-planning process. All personnel should
be aware that erection of any precast element is potentially hazardous and the purpose of the
preplanning process is to identify hazards and control any risk in the erection process. Although the
risks may be small, the consequences of a failure can be death. Serious injury or damage to the building
or equipment.

The main contractor must determine that the erection platform (floor slab, footing, suspended slab or
surrounding ground, etc.) can support the construction and erection loads and provide verification to
the crane owner/ operator prior to the commencement of the work.

lf a suspended slab is use to support the crane, or transporter, the slab should be designed for the
crane point loads, wheel loads, or any other construction loads by a registered engineer. A temporary
propping system may be required. Temporary supports, jointing and bedding materials, fixings and tools
should be pre-positioned at the fixing point. All temporary wedges, shims, and spacers and other item
not designed for permanent inclusion in the structure should be removed and the spaces made good
as necessary.

3.2 Erection preparation

Prior to commencing the handling and/or erection of precast concrete elements, the following items
should be considered by the precaster or main contractor as appropriate:

a) Check crane access to the site and erection platform to prevent cranes or trucks damaging the
concrete floor during access. A compacted hard-fill ramp at a suitable gradient should be provided to a
level slightly above the concrete floor;

b) Obtain verification that the erection platform can support the erection loads;

c) Ensure the locating dowels and leveling shims are correctly located. Dowels rather than blocks should
be used to restrain the base of face-lifted panels when they are being positioned;

d) Clear the site for truck and crane access ensuring room for crane outriggers, counterweight tail swing,
boom swing and under hook and overhead obstructions;

e) Ensure that sufficient space is available for precast propping or panel bracing:

f) Ensure that adequate temporary base restraint is provided for any precast element to prevent a sliding
failure (kick out) at the base or support of the element;

g) check that the means of temporary support, including false work is adequate for the intended purpose
and located correctly prior to the precast elements being placed;

h) Verify that the concrete has obtained the specified strength for lifting. This may already have been
done if the element was manufactured off-site: and

i) Check that the lifting inserts are in their correct location and that recesses are cleaned out in
preparation for lifting.

Note: If incorrectly located, faulty or missing lifting insert are identified, immediate contact should be made with the
designer who will rectify the problem and/or provide an appropriate solution

24
The actual lifting of the panels is the time when potential for disaster is highest. Due to their large surface
area and mass a great deal of care needs to be taken when lifting, moving and securing panels into
position. The likelihood for fatalities if a panel falls over is considerable. Increasing the risk is the fact
that the mobile crane may fall over and other panels that are struck by the crane or falling panel are
also likely to collapse. A domino effect can occur. With these factors in mind, it is extremely important
that both the panel erection crew and crane operator are highly skilled and experienced in the erection
of panels.

3.3 Planning cranage requirements

The selection of an appropriate mobile crane, preparation of the site and correct location of the crane
are crucial in ensuring the safe erection of concrete panels. Mobile cranes used for this type of
construction are usually required to work close to their maximum capacity and with high luff angles and
boom lengths due to the large size and mass of concrete panels. These factors increase the likelihood
of the crane overturning, particularly if the ground is not level. All cranes used for the lifting and erection
of tilt-up panels must be fitted with load indicators

Cranage planning should commence as clearly as possible in development of the work or project. A
trial erection operation should be considered to identify any unforeseen erection difficulties. Designers
and engineers must give consideration to crane loadings and access at the initial design stage,
especially where cranes may be supported on concrete slabs.

At appropriate stages, the planning process must consider:

a) Various stages including initial design, main contractor site set out, stage immediately prior to the
crane's use;

b) Consultation with the installer,

c) Precast element sizes

c) Crane selection, access to construction site and sitting;

d) Ground support conditions and the location of any excavations or underground services likely to be
adversely effected by imposed crane loads;

e) Proximity of overhead power lines;

f) Written procedures for setting up and dismantling of the crane and the lifting method as well as a risk
assessment of these procedures;

g) The make-up of the crane crew appropriate to the particular circumstances of the job;

h) The communication system;

i) Selection of lifting gear including appropriate snatch block for rotation of panels while suspended if
rotation is to be carried out (snatch blocks and other sheave blocks with standard main bearings are
not intended to be rotated under load. Thrust races or separate swivel bearings must be used);

j) Personal protective equipment for the rigging crew;

k) Emergency procedures; and

l) Protection of the public.

25
3.4 Rigging

Setting up a rigging system for erecting precast elements requires careful and thorough pre-planning.
It is normal for a competent person to supply an insert layout and rigging plan which has been based
upon the design of the panels for lifting. This must be available to a competent operator or supervisor
on site to ensure that the rigging adopted conforms to the lifting design. Special care must be taken
with rigging arrangements where unequal insert loadings have been used for the panel design.

The rigging system must distribute equal loads to all lifting points unless specifically designated
otherwise on the approved shop drawings and should include the use of slings running through sheaves
on spreader or lifting beams. Figure 16 and Figure 17 illustrate the use of spreader or lifting beams to
assist in distributing the load onto the lifting points.

Figure 16 Crane lifting and rigging system

Figure 17 Lifting of precast U-drain (Source: Pintas Trading)

Where offset lifting arrangements are used, the increase in load applied to particular lifting inserts must
be taken into account in selecting the capacity of the lifting insert. The use of spreader beam can
eliminate the use of rolling blocks. The specification of the spreader beam shall be noted in the shop
drawing or refer to the design engineer for appropriate steel section.

26
Sling lengths are critical where the rigging system includes the use of spreader beams or lifting beams
with slings running through sheaves. The rigging system must be designed to suit the spacing and
layout of the lifting inserts

Single, double and four leg slings are commonly used in the handling of elements. In selecting the sling
capacity, the increased force due to inclination of the sling and the change of direction at reeving points
should be considered. The included angle between slings at reeving points should not exceed 120
degrees.

Any two legs of the slings must be capable of supporting the total load when lifting precast elements
with fixed length multi-legged slings. Figure 18 shows some other possible configuration for lifting
precast concrete elements.

Figure 18 Examples of possible rigging configuration for lifting precast concrete elements (Source:
Safework with precast concrete New Zealand)

Lifts desirably should be planned so that rotation of snatch-block swivels under load is not required.
Where the snatch block is required to rotate it must have thrust races or separate swivel bearings.

An inspection and check of rigging must be performed prior to lifting by the rigger in charge. Especially
where steel wire rope is being used in the rigging system. This inspection includes a visual check to
ensure the snatch block collar pin is intact and the collar has not become loose.

27
Where blocks with lockable clamp balls are not available, care must be taken to ensure that the cheek
plates clamp bolt is fully tightened and that rubbing and abrasion under load does not occur. See Figure
19.

Figure 19 Rigging system

The rigging system should be arranged to allow the precast element to lie in or near its correct attitude
for erection into the structure. This can be accomplished through one or more of the following means:

a) Appropriate location of the lifting inserts;

b) Correct location of the slinging point or points in the element;

c) Use of a lifting beam with offset lifting points; and

d) Use of a counterweight.

Where precast elements need to be rotated through 90 degrees by use of a tailing lifter (lifting insert at
the bottom of the element), the required capacity of the crane winch being used to rotate the element
must be determined (refer Figure 20).

Up to 70% of the mass of the element can be taken by the tail lifter during rotation. This is particularly
critical for edge lifted wall panels. Panels should be rotated such that the panel is suspended in its
rotated position by the main switch, if one crane is used, or the larger capacity crane if two are used.
Where one crane is used each winch drive should be independent. This rotation procedure requires a
great deal of skill by crane operators. Components of the rigging system including lifting gear and slings
must be checked regularly far damage and excessive wear, corrosion, etc. to ensure it is appropriate
for the loads being lifted. Regular inspection of the lifting clutches must be carried out to check for wear
and deformation.

28
 Figure 20 Rigging system

3.5 Exclusion zone

Only persons directly involved with the erection of panels should be located in the area while lifting is
taking place. Such persons must avoid being in a position where they could be struck in the event of a
crane or panel falling over.

In precast construction the risk to persons is significant because:

a) Panels are very susceptible to wind loads because of their shape and size;

b) If a panel falls over or an insert fails, while the panel is attached to the crane, it is very likely that the
crane will overturn. Other panels may also be struck and fall over. The potential consequences of an
incident are therefore usually more serious than when other items are lifted: and

c) There is usually greater risk when lifting a concrete element (i.e. than a steel object) because the
integrity of the load relies on a number of factors such as concrete strength, steel content and position,
lifting insert integrity and correct operation of the lifting clutch. Due to the greater number of variables
there is a greater risk.

All members of the public and workers not involved in the erection of panels must be prevented from
accessing the erection area. An exclusion zone should be set up that prevents unauthorized persons
gaining access. On some jobs this may necessitate the erection of parawebbing, signage and/or fencing
depending on the ease of access and the likely presence of workers or members of the public.

Where a road or other vehicular access way is located in the exclusion zone, traffic should be prevented
from passing through the zone while panels are being lifted and prior to securing the panels with braces.

3.6 Installation platform

Before installation process commences, the main contractor must supply the installer with written
verification from the project design engineer that the erection platform (floor slab, suspended slab,
surrounding ground, etc.) can safely carry the construction and installation loads.

Backfilled excavations and trenches must be identified and assessed. Additional measures, such as
the provision of timber mats, may need to be taken to ensure that any backfilling can support the
construction and installation loads.

If a suspended slab is used to support the crane, the slab should be designed for the crane point loads.
A suitable propping system may be required and, if so, must be designed in accordance with the
requirements of the appropriate Standards.

29
3.7 Installation sequence

It is essential that the order in which the various components and members of the structure are
assembled will maintain stability at all stages, allowing for the effects of high winds on partially
completed structures. Overnight it may be necessary to stabilize incomplete structures with well
anchored and correctly tensioned flexible steel wire ropes.

Elements must not be lifted or installed before attaining the minimum concrete strength on the approved
shop drawings for lifting or erection unless the concrete in the specific elements has been tested to
confirm that the design strength for installation has been attained. Test results must be available on site
prior to erecting the element.

The dead weight of all elements should be calculated or weighed prior to the commencement of
erection, and this information made available to the erection crew. The lifting and placing method must
ensure that a sudden failure of the element or rigging will not endanger the crane operator or the crane.
Under no circumstances should personnel pass or stand beneath a suspended element.

The lifting equipment should be attached to the precast elements by a competent person and the
immediate area cleared in preparation for lifting. Figure 21 shows precast concrete being fixed in place
by a personnel. Taglines may be required in some circumstances to stabilize the load that might rotate
or swing in an uncontrolled fashion. Effect of wind also need to be considered upon safe handling of
the precast elements

The erection design engineer must determine the configuration of the rigging lifting equipment in
consultation with the installer.

Installation of Vertical Precast Concrete Components

The method and sequence of installing the precast wall panel and also other vertical panel are
discussed in this chapter.

1. Set the reference line and offset line to determine the position of precast elements to be installed
2. Provide level pads for setting the level of the elements. Set the level pads in position using non-
shrink mortar
3. For precast external wall/column, fix the compressible form or backer rod on the outer perimeter of
wall.
4. Lift and rig the panel to its designated location with use of wire ropes
5. Adjust the panel to position and secure it with diagonal props
6. Prepare and apply non-shrink mortar to seal the gaps long the bottom edge of the inner side of the
panel
7. For corrugated pipe sleeve or splice sleeve connection, prepare and pour non-shrink route or
proprietary grout into the pipe inlets provided
8. Keep the installed panel undisturbed for at least 24 hours
9. For panels with cast in-situ joints, install the joint rebars as required
10. Set up forms for the casting of the vertical joint
11. Carry out concrete casting
12. Remove forms after sufficient concrete strength has been achieved
13. For joints between façade walls or between external columns with beams or walls elements,
approved sealant and rout will be installed at later stage
14. For panel with welded connection, place the connecting plate between the panels and carry out
welding as per design requirement.

30
 Figure 21 Lifting of precast element to its designated position (Source: Creative Precast)

Installation of Horizontal Precast Concrete Components

The method and sequence of installing horizontal precast concrete components (includes slabs and
beams) are discussed in this chapter.

1. Set reference line and offset line to determine the required alignment and level of the precast
slab/beam elements during installation
2. Put up temporary props to support the precast slab/beam elements
3. Lift and rig the elements to designated location with the use of wire ropes
4. Align and check level to suite the required setting out before placement of precast members to final
position
5. For components with cast in-situ joints, place and lap the rebars as required
6. Set up the formwork for the casting of the joints
7. Carry out concrete casting
8. Remove forms after sufficient concrete strength has been achieved.

3.8 Leveling shims

Leveling shims carry the load of the precast concrete element that must be supported adequately to
prevent movement until it is incorporated in the main structure. They are to be manufactured from a
suitable durable material and shall have adequate strength to carry the full imposed loads.

Note: Direct concrete to concrete, or concrete to steel bearing should be avoided unless some edge spalling and
cracking is acceptable

31
 Shimming should be limited to a maximum height of 50 mm and a minimum width of 100 mm unless
specifically designed otherwise. Where the total shim height is greater than 50 mm, extra care must be
taken to ensure stability. Shims should be located at least 300 mm in from the ends of the element and
bearing support unless otherwise specified. This is particularly relevant far thin wall panels where edge
breakout can occur if shims are placed too close to bottom corners. Figure 22 illustrate the use of
levelling shims between concrete panel and footing.

Figure 22 Leveling shims (Source: Safework with precast concrete New Zealand)

Direct concrete-to-concrete, or concrete-to-steel bearing should be avoided unless some edge spalling
and cracking is acceptable to the main contractor and project design engineer.

The gap between the bottom of the element and the footing must ultimately be grouted or dry packed,
to transfer the load to the footings.

3.9 Fixing inserts

Fixing inserts for the panel connection to roof framing and other structural members must be designed in
accordance with the appropriate standard to resist the forces imposed on the connections. These forces
can be very large in the case of pitched rafters which may result in inward or outward lateral forces
overloading panels and connections if not properly designed.

Where possible, fixings should be standardized for all panels on an individual project to minimize the
chance of error. Where permanent fixings or connections are to be utilized for temporary use during
construction, the main contractor or the installer should verify that the fixings are suitable for the
temporary use and that such use will not compromise their long-term performance.

3.10 Missing and unusable lifting points

If incorrectly located, faulty or missing lifting inserts are identified, immediate contact should be made
with the designer who will rectify the problem and identify an alternative solution.

32
Solutions could include:

a) Fixing a plate with undercut anchors;

b) Fixing a plate with expansion anchors. If using expansion anchors;

c) Fixing a plate with chemical anchors. Anchors must be individually proof tested; and

d) Drilling through the element and attaching lifting plate(s) by bolting;

3.11 Temporary bracing

Braces are temporary components providing stability in preventing a precast concrete element from
overturning. All elements must be braced in accordance with the requirements of the approved shop
drawings. The approved shop drawings must specify the required bracing forces and show details of
the fixings to the element and the bracing footing.

Braces must be maintained and inspected between each use to ensure that all components are correct
and in good working order. Brace feet or shoes must be of a type that will physically prevent lateral
displacement of the shoe from the insert connections after installation. Wherever possible bracing
should be fixed to the element before lifting.

When it is necessary to attach the braces after the element has been positioned, the element should
be held safely by the crane whilst the braces are installed on the upper face by the use of a ladder or
alternative access system.

Generally, a minimum of two braces should be used for all elements. Where elements can be effectively
coupled together one central brace to resist rotation or toppling may be sufficient subject to design by
a registered engineer. Braces shall be attached to a flat surface which is capable of withstanding the
applied load. Figure 23 shows usage of temporary bracing for a precast concrete column.

Figure 23 Temporary bracing of precast column (Source: Creative Precast)

33
Base restraint prevents a sliding failure (a panel kicking in or kicking out) during precast concrete
erection. There should be sufficient temporary base restraint to prevent a sliding failure at the base or
support of the precast concrete element until the element is secured. Note that the panel weight may
not provide base restraint.

Bracing bolts should be checked at regular intervals and immediately after any occurrence such as an
earthquake or storm.

Note: All equipment used in conjunction with the handling, transportation and installation of a precast component
must be maintain a high standard and be suitable for its intended

Braces must be marked and the mark shall include the supplier, the model, specification of the braces
and the batch to assist in identification.

Brace adjustment mechanisms must have stops on the threads to prevent over-extension and retaining
devices to prevent unintentional dislodgment of the shear pins. The shear pins should be constructed
so that they cannot be undone without the use of a tool.

Bracing design must consider dead load, construction live load, impact load and horizontal load.
Construction live load shall consist of:

a) Actual weight of any equipment to be supported

b) Uniform load of 1.0kN/m2, applied over the area supported and extending 600mm past the edge of
coping
c) Vertical force of 0.1kN/m, applied at a distance of 150mm outside the face of coping over a 9.0m
length of the deck centered with the finishing machine

Impact load consist of load from impact during placement operations and load subject to impact during
lifting operation. In case members subject to impact during placement operation, the dead load will be
considered and 1.3 shall be used as a factor of safety. In case members subject to impact during lifting
operation, the static load will be considered and 1.3 shall be used as a factor of safety.

Horizontal design load shall consist of the sum of any actual horizontal loads due to equipment,
construction sequence, or other causes, excluding the specified wind load, but in no case shall the
horizontal design load be less than 2% of the total dead load to be supported at the point under
consideration.

3.12 Bracing insert

Bracing insert capacities should be designed based on:

a) The method of installation;

b) The strength at the concrete into which they are placed; and

c) The distance from the insert to the edge of the element.

34
 Figure 24 Correct method of placing inserts

Unless specified otherwise in the shop drawings, bracing inserts must not be closer than 300mm to the
edge of the element, footing or other bracing support. Figure 24 shows the correct method to place a
lifting inserts inside the precast concrete element before casting.

During the lifting process, the braces should not hang below the base level of the element. This may be
achieved by the use of adjustable brace lengths or by the use of taglines. For face lifted wall panels,
bracing inserts should be on the same face of the panel as the lifting inserts.

Generally, a minimum of two braces should be used for all precast elements. Two braces may not be
necessary where elements are provided with erection brackets or permanent connections to other
restrained elements such as steel portal columns or precast walls forming a stable "box" structure. In
other situations, where expansion anchors are used in brace footings, the braces may be required on
large panels since the expansion anchor capacity may limit the capacity of the brace.

After erection, it is the main contractor's responsibility to check braces, bracing balls and pins at regular
intervals to ensure they maintain the required capacity. A check of the torque of the bolts should be
made 24 hours after erection and at regular intervals after installation.

Superimposed loads must not be applied to the panels in braced positions unless such loads have been
specifically allowed for in the design. These include loads from erection of steelwork, floor units and
other attachments. Lateral outward forces on panels during the erection of pitched rafters can result in
overloading of temporary bracing and its connections such as inserts and balls. As well, substantial
inward forces may be imposed on panels and fixings to steelwork as a result of temporarily unrestrained
steel rafters rotating and moving sideways under self-weight and erection loads. The resulting tensile
forces may overload fixing inserts and braces.

Prior to the removal of braces, it is the responsibility of the erection design engineer or the project
design engineer to inspect the structure to ensure that all structural elements effecting stability are
securely fixed to the precast concrete elements. A written instruction authorizing the removal of the
braces should then be supplied.

It is the responsibility of the main contractor to ensure that no brace is removed without written
instructions from the erection design engineer or project design engineer.

35
3.13 Temporary propping

Props are temporary components supporting loads which produce compression forces. Braces used to
support precast concrete panels during erection must not be used as props. Propping systems must
allow for possible construction process changes to the distribution of loads during the process.

Where beams are post-tensioned after erection, the stressing process will change the shape of the
member, thereby reducing the load on some props and increasing the load to others. This particularly
applies where the stressing induces a camber into the beam which can lift the beam off props at mid-
span, transferring all the load to the props at the ends.

Where the scaling for precast beams cannot transfer loads during construction, the beams must be
propped at each end to carry the full load.

Where beams are to have floor systems placed on them prior to the beams being fully built into the
structure, allowance should be made for uneven loading on the beam during construction. With floor
units placed only on one side of a beam additional temporary propping may be required to each edge
of the beam. Without this consideration, overturning might occur as shown in Figure 25.

Figure 25 Uneven erection loading

Where required, all temporary propping should be in place and fully braced prior to commencement of
erection of any precast elements. Unless specifically detailed otherwise, temporary propping must
provide full support of all construction loads including the full self-weight of the completed floor system
and possible local concentrations of load during construction. Construction loads may include
reinforcing steel or excess concrete. Subject to the precaster's work method statement, it may be
satisfactory to erect temporary props after the precast floor units are in place, and for the props to take
only a portion of the full construction load.

Props must be vertical. They may also require bracing to prevent sideway of the whole assembly and
the buckling of individual props. Props must be adequately seated, leveled and capable of transferring
the full load through whatever structure they are bearing on and into the ground without adverse
settlement. The approved shop drawings must clearly specify the required propping forces and show
details of the fixing to the precast element and the prop footing. Prop footings are to be in accordance
with the requirements of the approved shop drawings and, in particular, the specified concrete strength
of the footing at the time of erection.

Prior to the removal of props, it is the responsibility of the erection design engineer or project design
engineer to inspect the structure to ensure that all structural elements effecting stability are securely
fixed to the precast concrete elements. A written instruction must be supplied prior to the removal of
props. It is the responsibility of the main contractor to ensure that no prop is removed without written
instructions from the erection design engineer or project design engineer.

36
 Propping of beams

Propping for beams should allow for possible changes to the distribution of loads during the construction
process.

Where beams are post tensioned the stressing process can change the shape of the ember thereby
reducing the load on some props and increasing the load to others. This particularly applies where the
stressing induces a camber into the beam which can lift the beam off props at mid-span transferring all
the load to the props at the ends.

Precast shell beams are normally pre-stressed which induces a natural camber into the units. In some
cases, propping is lowered slightly at mid-span to allow the beams to deflect to a more level shape
during placing of the concrete core and topping to the floors. This will result in a much higher than
anticipated load being carried through the temporary props at the ends.

The sealing for precast beams may not be suitable to transfer high loads during construction and the
beams will normally require full propping at each end.

If the designer of the structure requires the beams to be supported without the use of mid-span props
(to reduce the end support dead load pending moments), then the required must be clearly noted on
the contract drawings and on the precast layout drawings.

Where beams are to have floor systems placed on them prior to the beams being fully built into the
structure, allowance should be made for the fact that the beam may not be evenly loaded by the floor
units during construction. Long-span floor units placed on one side only of a beam may cause the beam
to roll on the props. For this reason, each edge of the beam may require temporary propping.

Where beams are to support floor units, allowance must be made for the beams to carry an appropriate
proportion of the construction load from the floor. Propping for the floor may in some cases be intended
to only even out the levels of the underside of the floor units and not to take any significant floor load
during construction. This can lead to a higher than anticipated load being carried through the beam
propping. Unless specifically noted otherwise, all temporary propping should be in place, adjusted to
the correct levels allowing for any required cambers, and fully braced prior to commencement of
erection of any precast beams.

Propping of precast floor systems

Refer to the floor system designers for the number and position of temporary support points, if any,
required for each unit during erection and construction of the floor. Loads to the propping should be
calculated by a competent person. Unless specifically noted otherwise, temporary propping should
provide full support of all construction loads including the full self-weight of the completed floor system
and possible local concentrations of load during construction. Construction loads may include pallets of
infills stacked on the partially constructed floor, reinforcing steel or mesh, excess concrete before being
spread and leveled and other loads.

Unless specifically noted otherwise, all temporary propping should be in place, adjusted to the correct
levels allowing for any required cambers, and fully braced prior to commencement of erection of any
floor units.

Floor units such as the various hollow-core systems which are normally erected without temporary
props, may require some amount of temporary propping at mid-span principally to even out the natural
variation in carters of the units, or further structural cosmetic reasons with the specific approval of the
foot system supplier in each particular instance, it may be satisfactory to erect the temporary props after
the precast floor units are in place, and tor the props to take only a portion of the full construction load.

37
Propping to floor units should have a stable top bearer. This top bearer should be located in the header
of the props in such a way as to prevent rolling of the bearer and to ensure that the load from the bearer
is transferred concentrically into the prop. The load bearer should be over the center line of the prop
otherwise it may cause the prop to bend leading to failure. Props should be adequately scaled, leveled
and capable of transferring the full load through whatever structure they are bearing on and into the
ground without unacceptable settlement.

If props are required, they should be constructed vertically. They should also be braced to prevent side-
sway of the whole assembly and the buckling of individual props.

Temporary supports for precast cladding

Temporary headtrees should be adequate for all the construction loads, including wind to be sustained
and should be securely but temporarily fixed and easily removed. They should be rigid and independent
of movement of the scaffolding.

Where the supports are of timber or metal, care should be taken by means of backing and polyethylene
sheeting or non-staining protective materials to protect any units on which they rest from staining and
damage.

38
SECTION 4 : SAFETY AND RISK MANAGEMENT

4.1 General

Safety in site operation is the utmost concern that need to be considered by all respected personnel.
Besides, safety is one of the main objectives in delivering a good project. The most common safety
hazard in erection of precast concrete elements is working at height. Thus, it is very essential for related
personnel to consider all the related safety hazards during the work.

This section mainly covers on working at height in erecting the precast concrete elements. It includes
reduction of work at heights, limitation on work at heights, selection of access too working places,
vertical movement on steelwork, horizontal movement, ladders, work platforms, personnel boxes, fall
protection, safety harnesses and anchorage techniques and personal protective method.

It is more practical that this standard to be referred along with the Guidelines on Occupational Safety
and Health in Construction Industry (Management) (OSHCIM), 2019 and the Guidelines for Hazard
Identification, Risk Assessment and Risk Control (HIRARC), 2008.

4.2 Safety Consideration

Weather

Adverse weather conditions can make steel erection hazardous and unsafe. Weather conditions which
have an adverse effect on erection safety include:

a) Rain or dew;

b) Wind;

c) Conditions which cause poor visibility such as fog, haze, mist or glare.

Under such conditions, erection operations which become unsafe should be stopped, unless adequate
measures are taken to ensure that the risk is no worse than under normal weather conditions.

If, under adverse weather conditions, the decision is made to stop work, measures should be taken to
ensure the stability of the structure. Similarly, the stability of previously erected steelwork should be
reassessed before work is restarted.

Lighting

Adequate natural and/or other lighting shall be provided to all areas where work is to be carried out.

Maintenance of Equipment

Safety features built into tools and equipment are only as good as the safety practices of those using
them. The employer shall ensure that regular inspection and maintenance is carried out to ensure that
all tools and equipment, as well as plant and machinery, used in the erection of steelwork are always
in good condition and safe to use. Each type of plant or equipment should be used as intended and
within the limits of its rated capacity.

Safety Helmets

The wearing of a safety helmet is compulsory in areas designated as hard hat areas.

39
 Footwear

Persons erecting steel should wear non-slip footwear. Rubber soled shoes can be a hazard where
wet or slippery steelwork or surfaces are encountered. Consequently, work should not proceed during
wet weather or until such surfaces are dry, unless some other safe method of erection is employed.

4.3 Identify the hazard

First, identify the hazards. Many things can pose a hazard in a construction project, such as deficient
design of steel structure, faulty steel material, and unauthorized modifications to steel components,
poor lifting practices and inadequate temporary support. Consider each stage of the project lifecycle
and identify potential hazards. For example:

a) Review proprietary documentation such as designer’s safety reports, design drawings, shop
drawings and erection instructions to identify hazardous tasks and the sequence of work.

b) Observe work locations and look for interactions with other activities, vehicles, pedestrians, structures
or underground essential services.

c) Consider the environment and check for features such as sloping ground, rough surfaces, holes,
excavations, trees, underground watercourses or other structures.

d) Review any inspection, maintenance, incident and injury records, including information on near
misses.

e) Review high risk construction work needs. Information about hazards should be recorded and given
to those involved in later stages of the structure’s lifecycle to enable effective consultation and risk
management.

4.4 Assess the risks

If a hazard has been identified, the contractor or person involved should use a risk assessment to
determine how large the risk posed by the hazard is, what action is necessary to control the risk, how
urgently the action needs to be taken and who is responsible for implementing the control measure. In
some cases the risks and related control measures will be well known, but in other cases a more
comprehensive assessment will be required.

4.5 Control the risk

The contractor must eliminate risks, so far as is reasonably practicable. Eliminating a risk means
removing it from the workplace. If elimination is not reasonably practicable, consider options in
accordance with the hierarchy of risk control. The hierarchy of controls requires the highest level of
controls to be implemented first, so far as is reasonably practicable:

a) Substitute a high risk activity with a low risk activity – for example use an element connection system
instead of relying on welding.

b) Isolate the hazard – for example use an exclusion zone to separate workers from mobile plant that
is erecting prefabricated concrete elements.

c) Implement engineering controls – for example provide overhead protective structures to prevent
objects falling and hitting people below the work area.

If it is not reasonably practicable to minimise the risk through substitution, isolation or engineering
controls, the risks must be minimised through lower level controls:

40
 a) Introduce administrative controls – for example stop construction work at designated hold points until
engineering approval is obtained to progress to the next step of the process.

b) Use PPE – for example wear high visibility clothing, hard hats, protective hand and footwear. Use
PPE in addition to higher level controls when some risk still remains.

4.6 Maintain and review the control measures

The contractor should review control measures regularly to ensure they are working as planned and
that risks are managed so far as is reasonably practicable. Consider any changes, the nature and
duration of work and whether the system is working as planned. When reviewing control measures,
review and revise any method statements that have been prepared in relation to high risk construction
work.

4.7 Working at Height

Reduction of work at heights

Whenever possible the need to work at heights should be avoided, to minimize the risk of falls. Some
alternative means of erection which may reduce the need to work at heights are:

a) Connecting as much steelwork as possible at ground level, from erected floor slabs or from decks in
the structure. This should be planned and included in the erection scheme;

b) Reducing the number of separate components lifted by connecting where practicable at ground level;

c) Using a remote release lifting device on the lifting gear where possible.

d) Inspecting and testing as much as possible at ground level.

Limitation on work at Heights

Where work at heights is unavoidable, steel erectors shall ensure that employees have safe means of
access to working positions. Steel erectors shall ensure that workers are suitably secured or otherwise
protected against falling.

The method selected for the protection of employees will generally be determined by individual job
factors including the nature of the work, the size of the job, equipment availability, interaction with other
trades and the like. Methods of protection available include scaffolding, ladders, scissor hoists,
personnel boxes, safety nets, cherry pickers and safety harnesses.

Traversing steel beams, rafters, or similar structural components should be avoided except where the
worker is:

a) Working above scaffolding or similar structure, with a working platform not more than 2 meters; below
the worker; or

b) Wearing a safety harness securely attached to a static line

c) Walking immediately above a safety net; or

41
d) Straddling an I-section beam which is deep enough, within a range 200 to 700mm, to allow
comfortable movement along the bottom flange and enable access to the working position. In such
cases both hands must be free to grip the top flange.

Selection of access to Working Places

The following sections outline ways in which safe access and protection from falls may be achieved
while working at heights.

Annex A describes types of access to working places with conditions, comments and examples of their
use.

The sequence of erection should be planned so that the permanent structure can be used as much as
possible to provide safer access ways and working places, with little or no adaptation.

Access to working places should be restricted to persons actually engaged in work in that area. In
choosing a particular method of access to a working place, consideration should be given to:

a) Ground conditions. A greater variety of access aids, for example scissor lifts, can be used if suitable
hard standings or floor slabs are provided;

b) Any permanent access routes, such as stairways that could only be erected as construction
progresses;

c) Permanent access floors, if these are erected as the structure progresses;

d) Height and accessibility of connections;

e) The number of times access is required, including any necessary supervision and inspection;

f) The type of activity, tools to be used, and how long the activity will take;

g) The type of labour required to undertake the work i.e.; certified steel riggers and their supervision, or
other employees;

h) The availability of, and the clearances required for, any plant or equipment to be used;

i) The need to move access ways as the job progresses to form the shortest possible route;

j) Any abnormal site conditions (e.g.; unloading restrictions, limited hours of working, likely prevailing
wind conditions).

Vertical Movement on Steelwork

Stairs, ladders, or appropriate mechanical equipment such as personnel boxes, should normally be
used for vertical movement above four meters. Proprietary equipment is available. The use of cranes
and skylift to carry out the activities shall be visually inspected prior to commencement of operation in
accordance of crane or skylift inspection checklist. Riding of crane hooks or loads being hoisted is not
permitted.

Operator of the scissor lift (EWP), sky-lift and other working platform shall have a valid driving license
issued RTD and are familiar with the safe operation of respective machine. The work on respective
machine shall follow the manual issued by the machine’s company and Best Practice on Occupational
Safety and Health in Construction Industry 2019.

42
 Horizontal Movement

Horizontal movement along beams may be required to reach a work area or to carry out the erection of
building components. Such horizontal movement may be executed in any of the following ways:

Walking the top surface

Walking along the top surface of a beam by competent steel riggers is an acceptable means of
horizontal movement providing the person can fall no more than four meters (refer Figure 26).

Figure 26 Worker walking on a beam

The beam should be fixed, be sufficiently stable to permit such walking along the top surface and have
a minimum width of 130mm. The top surface of the beam should be free from shear bolts, cleats, and
other obstructions. At a height above four meters, attachment by safety harness to a suitable anchorage
should be used. For beams inclined at a slope greater than 15 degrees, an alternate method of
movement should be used.

Beam straddling

Beam straddling is an acceptable means of horizontal movement to effect the erection of building
components, provided it is carried out on an I-section beam (refer Figure 27). The beam depth should
be between 200mm and 700mm to allow the steel rigger to conveniently sit or stand astride the top
flange with adequate hand and foot holds. Obstructions should not necessitate the steel rigger changing
the basic position described and it should be noted that the presence of shearbolts, cleats, and other
obstructions precludes safe passage.

Figure 27 Worker straddling on a beam

Beam straddling includes sitting astride the top flange of the beam or walking on the bottom flange while
straddling the top flange of the beam (refer Figure 28). For beams inclined at a slope greater than 30
degrees, an alternate method of movement should be used.

43
Walking the bottom flange

Walking or standing on the bottom flange means walking or standing completely on one side of the
beam or rafter and does not imply or include a straddling position. Walking the bottom flange of a beam
or rafter is an acceptable means of horizontal movement provided that:

a) A secure handhold can be easily and conveniently reached by the steel rigger using both hands:

b) A secure foothold is available for both feet and can be used in conjunction with the handhold position
without losing co-ordination; and

c) The top flange or surface does not reach higher than the steel rigger's chest

For beams or rafters inclined at a slope greater than 30 degrees an alternate method of movement
should be used.

Figure 28 Worker walking on bottom flange of an I - beam

Ladders

To attain temporary access, ladders may be used for the purpose of connections and for short term
operations such as the removal of lifting slings.

Portable ladders shall be placed on a firm base. The slope of the ladder shall be about one (horizontally)
to four (vertically).

Where the ladder is used for a short term work such as disengaging lifting slings, a second person
should stand at the bottom of the ladder in such a way as to prevent slippage.

Where the work is of longer duration, the ladder should be secured at the top and the worker secured
by means of a safety harness. Vertical ladders in excess of 9m in height should incorporate a fall
arresting device, for instance, the rigid rail system.

Attachment to a fall arrestor (See Figure 29) should occur from this height.

44
 Figure 29 Fall Arrestor

Work Platforms

There are different types of work platforms which may be used to attain access to steelwork. These are:

a) Temporary working platforms which can be fitted at ground level before erection. Design features of
such platforms should include easy and safe dismantling for re-use at other locations;

b) Lightweight, fabricated, hanging working platforms (See Figure 30) which can be used in many
locations if they are designed in such a way as to fit a variety of beam widths.

Figure 30 Hanging Work Platform

c) Elevating working platforms such as scissor lifts or cherry pickers which provide a safe working
platform suitable for tasks such as bolting up, purlin bridging and installation of sag rods.

The surface of working platforms and gangways shall be free of protrusions or obstructions and shall
be large enough and strong enough to carry the required loading of workers, tools and materials.
Working platforms should be able to resist other likely induced forces such as impact and environmental
conditions such as wind.

Personnel Boxes

Personnel boxes complying with the regulations can be used either to gain access onto the structure or
as working platforms. When used for access, the box should where possible, be landed on a firm, level

45
 surface which is wide enough to fully support it. People should enter or leave the box one at a time and
the alighting area should allow them to climb in and out of the box easily and safely. There should also
be a safe means of access to the place of work from the box. When boxes are used as a working
platform for making connections on an open framework, people should not attempt to leave the box at
height unless a safety harness is used by each steel rigger to secure themselves to the box or structure.

Fall Protection

I.Safety Nets

Safety nets may be a satisfactory alternative means of protection in the event of falling, while also
allowing steel riggers maximum flexibility of movement.

In considering the use of safety nets as a fall protection measure, main contractors may take into
account the usefulness of safety nets for the safety of persons in other occupations, for instance, roof
plumbers.

Safety nets should be constructed in accordance with safety and health regulation. The use and
maintenance of the nets should be in accordance with the safety and health regulation.

II. Floor Opening Protection

The floor opening on a floor surface should be covered by a specific material and specification with
respect to the opening sizes. The floor opening cover is categorized based on its size which is:

Table 2 Floor Opening Protection

a) Smaller than 250mm
b) Greater than 250mm but less
than 1500mm
c) Greater than 1500mm but less
than 4000mm
d) Greater than 4000mm but less
than 5000mm
e) Greater than 5000mm
18mm thick plywood and cover hole. The
plywood shall be fixed with concrete nails.
Use 2 timbers run across the hole and then
covered with 18mm thick plywood which fixed
with iron nails to the timber runs, the surface of
plywood shall painted with warning sign indicator
with red and white paints (spacing 20cm, angle
of 45 degrees)
Cover the opening with 10mm thick plywood, and
fixed with Ф8mm diameter expansion bolts or
cement nails, surface painted with warning sign
indicator with red and white paints (spacing
20cm, angle of 45 degrees)
Setup Ф48mm diameter steel pipe guard rails
around the hole, pole spacing not exceeding
2000mm, lower part of the protective railing set
200mm high and 18mm thick plywood toe board,
top railings at 1.1m height and middle railing at
600mm height, all components must have
painted warning sign indicator with red and white
(with 400mm Spacing), guard rails setup full of
safety net close to the wall and display warning
signboard at the top of a horizontal railing bar
"beware of falling" poster signs.
Install guard rails use same type of material,
same pattern of installation except that install
additional guard rail in the bottom to ensure the
rigidity of the guard rails
If encountered such scene of holes, should carry
out a special protection program with approval of
project manager.

46
III.Building Edge Protection
a) When the window edge height is less than or equal to 800mm, the lateral width greater than 2000mm,
it needs to set edge protection

b) The building edge protection must have a strong connection of vertical post

c) The structural column shall be hoop up with steel pipe and other corresponding part adopt the span
method that buckled on the floor level with expansion bolt plug

d) The entire protection components shall brush painted red and white as warning indicator stripes
spacing shall be 400mm

e) Every guardrails space between any toe-board and the lowest guard-rail above it shall not exceed
690 mm

f) Toe-boards up to a sufficient height being in no case less than 200 mm

g) Top rails protection height are between 900mm-1100mm

Safety Harnesses and Anchorage Techniques

Safety harness equipment must fit correctly and be kept in good order. Safety harnesses, as opposed
to belts, should be used because harnesses provide for better protection.

The safety line of the harness should be attached to the structure or a static line or other fixing point,
preferably above the working position to limit the height of any fall. Methods of attachment include:

a) Looping the safety line around a structural member and fastening the hook back onto the safety
line. The use of such a "choke hitch" is dependent on the overall size of the frame member
encompassed by the loop of the safety line or on the thickness of the extremities of the member
which may be small enough to cut the safety line if a fall should occur. In such cases the safety
line should be increased in thickness or be sleeved to prevent this cutting action;

b) Where frame members are too big to be choked around, a wire rope (minimum diameter 12.5mm)
may be secured around the member (preferably at ground level prior to erection) and the safety
line then attached to the wire rope itself;

c) Using proprietary girder grip devices. These may be:

I. Attached around, or onto a structural member of a suitable size range (See Figure 31); or

Figure 31 Steel Riggers Hook

47
II. Inserted into a suitable sized hole in the structural framework and locked to give a secure
anchorage. This use is dependent on there being a spare, correctly sized hole, and it should
therefore be included at the detailing stage. The frame material must also be suitable (see Figure
32).

Figure 32 Girder Grip Device

Fall protection may also be achieved by the use of a parachute type, full body safety harness, attached
at the top dorsal position by a safety line to a static line, through a suitable travelling anchorage,
provided that:

a) The persons required to use the equipment are well trained personnel and supervised in its use;
b) Persons using a safety harness are not working in isolation;
c) Safety harnesses comply with the safety and health regulation;
d) Harnesses and other equipment are maintained in accordance with safety and health regulation;
e) Static lines and anchorages are designed for strength and movement restraint allowing for a minimum
factor of safety of 6 with a minimum line diameter of 12.5mm;
f) the free fall limit for a person wearing a full body harness attached to a safety line behind the user's
head at the top of the back, does not exceed 1.8 meters, in accordance with safety and health
regulation;
g) Safety lines have a minimum tensile strength of 22 kN;
h) There is a minimum of stack in the safety line, between the person and the attachment to the static
line or other anchorage;
i) The anchorage used is as high as the equipment permits and the hazard of working above the point
of anchorage is emphasized to workers;
j) The rescue and evacuation of a worker who is suspended in a full body harness occurs as soon as
possible and in any event within twenty minutes of an arrested fall.

Personal Protective Method

Only to be used when other methods do not give required protection.

A. Safety Harnesses

Examples: Making connections when other means of assuring a safe place is not practicable.

Some Conditions of Use: Means of anchorage must be provided; correct length of safety line to be
used. Breaking strength of safety harnesses shall be tested not less than 22 kN.

Comments : The use of harnesses is preferred as this reduces injuries should a fall occur; harnesses
which incorporate tool frogs (a loop fastened to a belt to hold a tool) and pouches are to be encouraged.
Competent person to check and maintain.

48
B. Anchorage Methods to Structure

Example: To secure safety line of safety harness (a) in a free hole in structural steelwork, or (b) around
a structural member.

Some Conditions of Use: Inspected before use and attached properly before being relied upon

Comments: Single hand only required for attachment; and extra hole may have to be planned and left
open

C. Static Lines

Examples: For the attachment of a safety harness via a safety line and travelling anchorage.

Some Conditions of Use: Effective anchorages required; whole system should be designed for loads
which it is expected to take safely.

Comments: Use recommended only if direct fixing for safety line is not possible.

D. Safety Eyebolt

Examples to secure safety line of safety harness in, for example, concrete or masonry. Security of eye
bolt should be checked before use.

49
 Annex A

Access to Working Places

Access Mode Examples Condition of Use Comments

Walkways General Access Edge protection must be
and adequate; grating or
stairways flooring units must have
flush finish and be securely
fixed; they must be
maintained in a fit condition
and checked regularly.
All permanent
walkways, ladders and
steps should be
erected as early as
possible. Temporary
guard rails should be
used, if necessary, in
order to advance the
use of those means of
access if the
permanent rails are not
available (fixings may
need to be built in for
temporary provisions).

Vertical Access to columns Securely fixed along Fix to column prior to

Ladders length; Capable of safe
removal; at edge of
structure or over 9m high a
proprietary fall protection
system on the ladder
should be used
erection preferably on
faces within the
building line. Ladders
should be of good
construction without
defects; Spaces to be
allowed for toes behind
ladder.

Inclined General access to General access to heights

Ladder heights for bolting up of for bolting up of joints.
joints.
Rungs Access to tops of steel Properly designed and
Welded to columns (requires some fabricated; pitch (or
Columns other form of access to spacing) of flats should be
that point - such as a based on requirements for
ladder); access for ladders. A proprietary fall
maintenance if rungs protection system should
not removed on be incorporated on
completion of erection. columns in excess of 9m in
height.

Telescopic Access to, and making Firm and level purchase, Erection should be
Boom connections (particularly stable base; operators planned so that, for
Articulated for short duration should be trained and instance, previously
Arms (Single repetitive Work, such as competent to use the erected members will
Arm Scissor final bolt up). Inspection machine. not hinder the
Lifts) of completed or partially operation; ground
completed work. conditions for both use
and access to the point
of use should be
satisfactory; gives
increased speed of
access.
Personnel Access to, and making
Boxes connections on an open

50
 structure (particularly
beams to columns).

Tower Making connections. Firm foundation, sound, Ready-made,

Scaffolds Permanent and welded even surface; erected by
connections. qualified persons only;
height to base width can be
critical and should be
checked for stability; safe
means of access to
working places.
Swing Stage Remedial work on Outriggers to be of
completed structure. adequate length and
correctly counterweighted
or securely fixed to the
structure.
moveable access as
well as a working
place. Tower may need
to be secured.
Maximum load clearly
indicated. Fall arrest
device, on secondary
safety rope, to be
provided.

Bosun Chair Making connections Only to be used if access If bosun chair is used,
and Safety where access from from immediately below the occupant must be
Chair above is required. connection is secured to the
unreasonable. suspension rope.

Common or At connections where a Fabricated platforms need Removable platforms

Proprietary large number of to be properly designed can be lifted (empty) for
Scaffolds fasteners or welding is and constructed; must be reuse at a new
required. capable of being removed location. Fixed
safely. Method of platforms can be
connection to supporting attached to work-piece
member should not allow (e.g., to top of column)
accidental release or prior to erection.
removal.
Purpose Built At connections where a Removable platforms can Scaffold may be
Platform large number of be lifted (empty) for reuse erected with work-piece
(e.g.; fasteners or welding is at a new location. Fixed to avoid constructing
fabricated) required. platforms can be attached the working platform at
to work-piece (e.g., to top height.
of column) prior to erection.
Hung Atrium faces, below Properly constructed with
Scaffold core slip form suspension; inspected
assemblies regularly by competent
person.
Lightweight General Access; Must be adequately Can provide ready-
Staging working place; more supported; must not be made decking which
than one unit may able to move (or slide) can be moved readily;
“required to provide inadvertently; edge width can be increased
sufficient width for protection should be by providing extra
intended use. provided; safety harnesses units; requires fewer
or belts may be required if supports than scaffold
working below guard rail. boards. May need
securing against
movement.
Scaffold General access; Must be sound boards A regular check on
Planks working place; normally used in accordance with condition is required.
more than one plank will regulations. May need securing
be required to provide against movement.
sufficient width for
intended use.

51
ACKNOWLEDGEMENTS
Construction Industry Development Board, Malaysia would like to extend our sincere appreciation to all
those involved in the development of this standard:
Honorary advisor of Construction Industry Standard
Datuk Ir. Ahmad ‘Asri Abdul Hamid
Chairman of Construction Industry Standard Main Committee
Datuk Ir. Elias Ismail
Secretariat:
Ts. Dr. Gerald Sundaraj
Pn. Mazieana Che Amat
Ir. Qotrunnada Binti Abd Rahman
Ts. Dr. Hj. Mohd Khairolden Ghani
En. Ahmad Farhan Bin Roslan
Tc. Nuramin bin Baslan
Ts. Syed Hazni Bin Abd Gani
Prof. Madya Dr. Rozana Zakaria
Ts. Dr. Eeydzah Aminudin
Ts. Dr. Nor Hasanah Abdul Shukor Lim
Dr. Nur Izieadiana Binti Abidin
Dr. Nadirah Binti Darus
Prof. Madya. Dr. Rosli Noor Bin Noor Mohamed
Prof. Ir. Dr. Baharuddin Abdul Rahman
Prof. Madya Dr. Izni Syahrizal Bin Ibrahim
Prof Madya. Dr. Abdul Rahman Bin Mohd Sam
Mohd Fikri Bin Mohd Hanim
Sr. Dr. Siti Mazzuana Shamsuddin
Prof. Dr. Azmi Ibrahim
Ir. Muhd Salmizi Jaafar
En. Lim Kok Huat
En. Thong Chin Mun
En. Chua Lek Song
En Mohammad Ikram Bin Rizan
En. Mohd Hafiz Bin Mohd Ameran
En. Fadhlullah Mat Ali
Ir. Saiful Adli bin Abdul Karim
En. Foong Fatt Kee
En. Fakhrul Nazhi Hanaffi
Chief Executive, CIDB Malaysia
Deputy Chief Executive l, CIDB Malaysia
Construction Industry Development Board
Construction Industry Development Board
Jabatan Kerja Raya
Construction Research Institute of Malaysia
Construction Research Institute of Malaysia
Construction Research Institute of Malaysia
Construction Research Institute of Malaysia
Universiti Teknologi Malaysia
Universiti Teknologi Malaysia
Universiti Teknologi Malaysia
Universiti Teknologi Malaysia
Universiti Teknologi Malaysia
Universiti Teknologi Malaysia
Universiti Teknologi Malaysia
Universiti Teknologi Malaysia
Universiti Teknologi Malaysia
Universiti Teknologi Malaysia
Universiti Teknologi MARA
Universiti Teknologi MARA
Universiti Teknologi MARA
Creative Precast Products SDN BHD
Creative Precast Products SDN BHD
Chicano IBS Engineering Design (M) SDN BHD
Eastern Pretech (Malaysia) SDN BHD
Gamuda Industrial Building System SDN BHD
Green IBS Consult SDN BHD
Green IBS Consult SDN BHD
Setia Precast SDN BHD
Teraju Precast Services SDN BHD
52