Foreword

The Occupational Safety and Health Act 1984 established the Commission for Occupational
Safety and Health which comprises representatives of employers, unions, government and
experts. The Commission has the function of developing the legislation and supporting
guidance material and making recommendations to the Minister for implementation. To fulfil
its functions the Commission is empowered to establish advisory committees, hold public
enquiries and publish and disseminate information.
The Commission’s objective is to promote comprehensive and practical preventative
strategies that improve the working environment of Western Australians.
This code of practice has been developed through this tripartite consultative process and
the views of employers and unions along with those of government have been considered.
The following information should be read as background for understanding this code
of practice.

The Act
The Occupational Safety and Health Act 1984 provides for the promotion, co-ordination, administration
and enforcement of occupational safety and health in Western Australia.
With the objective of preventing occupational injuries and diseases, the Act places certain duties on employers,
employees, self-employed persons, manufacturers, designers, importers and suppliers.
In addition to the broad duties established by the Act, it is supported by a further tier of statute,
the regulations, together with lower tiers of non-statutory codes of practice and guidance notes.

Regulations
Regulations have the effect of spelling out the specific requirements of the legislation.
Regulations may prescribe minimum standards. They may have a general application or they
may define specific requirements related to a particular hazard or a particular type of work.
Regulations may also be for the licensing or granting of approvals, certificates, etc.

Codes of practice
A code of practice is defined in the Act as a document prepared for the purpose of providing practical
guidance on acceptable ways of achieving compliance with statutory duties and regulatory requirements.
Codes of practice:
• should be followed, unless there is another solution which achieves the same or better result; and
• can be used to support prosecution for non-compliance.

Guidance notes
A guidance note is an explanatory document issued by the Commission providing detailed information
on the requirements of legislation, regulations, standards or matters relating to occupational safety
and health.

Definitions
Appendix A defines the terms used in this code of practice.
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 AUTHORITY
This code of practice was approved by the Minister for Consumer and Employment
Protection pursuant to Section 57 of the Occupational Safety and Health Act 1984
on 10 November 2004.

SCOPE
This code of practice applies to all workplaces in Western Australia covered by the
Occupational Safety and Health Act 1984 where concrete wall panels, whether precast on
or off-site, or other precast concrete elements are used in the building and construction
industry.
It covers the areas of tilt-up and precast concrete construction where safety is a concern
including casting of panels and other precast elements, handling, storage, transportation,
lifting by crane, rigging systems and bracing and securing of panels.

WHO SHOULD USE THIS CODE OF PRACTICE?

This code should be used by designers, employers, contractors, self-employed persons,
managers, supervisors, persons in control of workplaces, employees and safety and health
representatives to assist them to comply with the Occupational Safety and Health Act 1984
and regulations where the tilt-up method of construction and precast concrete elements are
used on building and construction sites.
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 Table of contents
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7

PART 1: GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
1.1 Purpose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
1.2 Scope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
1.3 Regulations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
1.3.1 Notification to WorkSafe Western Australia Commissioner . 9
1.3.2 Documents on site . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
1.3.3 Workplan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
1.4 Relationship to Australian Standards . . . . . . . . . . . . . . . . . . . 10
1.5 Referenced documents and further reading . . . . . . . . . . . . . . . 10

PART 2: TRAINING, SUPERVISION AND HAZARD MANAGEMENT . . . . . . . . 11

2.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
2.2 Training and supervision . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
2.3 Safety and health . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
2.4 Hazard management . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

PART 3: MATERIALS, COMPONENTS AND EQUIPMENT . . . . . . . . . . . . . . 15

3.1 General – compatibility of components . . . . . . . . . . . . . . . . . . 16
3.2 Concrete and reinforcement specifications . . . . . . . . . . . . . . . . 16
3.3 Curing compounds and release agents . . . . . . . . . . . . . . . . . . 16
3.4 Lifting, bracing and fixing inserts . . . . . . . . . . . . . . . . . . . . . . 17
3.4.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
3.4.2 Lifting inserts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
3.4.3 Bracing inserts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
3.4.4 Fixing inserts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
3.4.5 Anchors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
3.5 Re-usable lifting equipment . . . . . . . . . . . . . . . . . . . . . . . . . 18
3.5.1 Strongbacks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
3.5.2 Lifting clutches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
3.6 Braces and props . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
3.7 Levelling pads and shims . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
3.8 Crane and rigging equipment . . . . . . . . . . . . . . . . . . . . . . . . 19
3.9 Proprietary documentation . . . . . . . . . . . . . . . . . . . . . . . . . . 20

PART 4: DESIGN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
4.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
4.2 Preplanning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
4.3 Design loads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
4.3.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
4.3.2 Suction loads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
4.3.3 Impact loads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
4.3.4 Wind loads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
4.3.5 Erection loads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
4.4 Building stability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
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 Table of contents (continued)

4.5 Structural design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

4.5.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
4.5.2 Fire . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
4.5.3 Design tolerances . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
4.6 Specification of concrete . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
4.7 Design for manufacture and erection . . . . . . . . . . . . . . . . . . . 26
4.7.1 Design and manufacture . . . . . . . . . . . . . . . . . . . . . . 26
4.7.2 Additional reinforcement . . . . . . . . . . . . . . . . . . . . . . 26
4.7.3 Design for erection . . . . . . . . . . . . . . . . . . . . . . . . . . 26
4.8 Panel thickness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
4.9 Slenderness effects . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
4.9.1 Panel height to thickness ratio . . . . . . . . . . . . . . . . . . 29
4.9.2 Dual lift slenderness design . . . . . . . . . . . . . . . . . . . . 29
4.10 Panel supports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
4.11 Fixing inserts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
4.12 Joints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
4.13 Brace footings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
4.13.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
4.13.2 Floor slabs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
4.13.3 Concrete blocks (deadman) . . . . . . . . . . . . . . . . . . . . 31
4.13.4 Other footings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
4.14 Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
4.14.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
4.14.2 Panel to panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
4.14.3 Panel to footing or floor slab . . . . . . . . . . . . . . . . . . . 33
4.14.4 Panel to structural steel . . . . . . . . . . . . . . . . . . . . . . 33
4.15 Strongbacks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

PART 5: DOCUMENTATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
5.1 Structural design drawings . . . . . . . . . . . . . . . . . . . . . . . . . . 36
5.2 Panel documentation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
5.2.1 Marking plan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
5.2.2 Shop drawings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
5.2.3 Erection documentation . . . . . . . . . . . . . . . . . . . . . . . 37
5.3 Lodgement of shop drawings with local government . . . . . . . . 37

PART 6: CASTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
6.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
6.2 Preplanning and layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
6.3 Casting bed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
6.4 Formwork . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
6.5 Tolerances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
6.6 Reinforcement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
6.7 Manufacturer’s statement and inspection . . . . . . . . . . . . . . . . 41
6.8 Placement and compaction of concrete . . . . . . . . . . . . . . . . . . 41
6.9 Curing and release agents . . . . . . . . . . . . . . . . . . . . . . . . . . 41
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 6.10 Lifting, bracing and fixing inserts . . . . . . . . . . . . . . . . . . . . . 42
6.11 Element identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
6.12 Stripping and repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

PART 7: HANDLING, STORAGE AND TRANSPORT . . . . . . . . . . . . . . . . . . 43

7.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
7.2 Handling and storage of site-cast concrete panels . . . . . . . . . . 44
7.3 Handling and storage of factory manufactured
concrete elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
7.4 Transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
7.4.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
7.4.2 Preplanning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
7.4.3 Loading . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
7.4.4 Support frames . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
7.4.5 Element protection . . . . . . . . . . . . . . . . . . . . . . . . . . 47
7.4.6 Delivery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

PART 8: ERECTION TO TEMPORARY BRACED CONDITION . . . . . . . . . . . . 48

8.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
8.2 Planning the construction and erection sequence . . . . . . . . . . 49
8.3 Work method statement . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
8.4 Exclusion zones . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
8.5 Crane standing area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
8.6 Planning cranage requirements . . . . . . . . . . . . . . . . . . . . . . . 51
8.7 Operating near overhead power lines . . . . . . . . . . . . . . . . . . 53
8.8 Operating near braces and panels . . . . . . . . . . . . . . . . . . . . . 55
8.9 Working at height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
8.10 Strongbacks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
8.11 Erection crew . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
8.12 Rigging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
8.13 Erection of concrete panels . . . . . . . . . . . . . . . . . . . . . . . . . 58
8.14 Modifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

PART 9: TEMPORARY BRACED CONDITION . . . . . . . . . . . . . . . . . . . . . . 60

9.1 Installation and inspection of temporary bracing . . . . . . . . . . . 61
9.2 Superimposed loads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
9.3 Levelling pads and shims . . . . . . . . . . . . . . . . . . . . . . . . . . 63
9.4 Grouting of the base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63

PART 10: INCORPORATION INTO FINAL STRUCTURE . . . . . . . . . . . . . . . . 64

10.1 Fixing to final structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
10.2 Inspection prior to and removal of braces . . . . . . . . . . . . . . . 65

APPENDIX A: Definitions of terms used in this code . . . . . . . . . . . . . . . . . 66

APPENDIX B: Sample documents, schedules and shop drawing . . . . . . . . . . 69

APPENDIX C: Referenced documents and further reading . . . . . . . . . . . . . . .77

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 Illustrations
FIGURES

3.1 Threaded insert

3.2 Load controlled expansion anchors
4.1 Recommended tolerances
4.2 Shear loads and tension loads in edge-lifted concrete panels
4.3 Preferred concrete panel rigging configurations
4.4 Panel rotation
4.5 Various typical panel connections
4.6 Strongbacks
6.1 Crane lifting radius
7.1 Horizontal stacking of factory manufactured concrete panels
8.1 Clearance for cranes from overhead power lines
8.2 High voltage contact
8.3 Snatch block
9.1 Concrete panel bracing, preferred arrangement
9.2 Corner bracing
9.3 Levelling shims
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 Introduction

Tilt-up and precast concrete construction is a method of prefabricating concrete in discrete

elements and erecting and incorporating them by crane into their final position in a structure.
This code of practice sets out industry-wide guidelines for establishing and maintaining a safe
working environment wherever tilt-up and precast concrete construction is used.
The tilt-up and precast concrete industry, from design to completion of construction, should be
aware of its obligations to protect employees, contractors and members of the public under
the Occupational Safety and Health Act 1984, regulations and codes of practice.
This code provides practical advice about the safe design, manufacture, transport, cranage,
storage, erection and stablilisation of concrete wall panels and other precast concrete
elements. The emphasis is on ensuring a safe working environment whenever these elements
are used.
Advice can also be found in Australian Standards and other documents referenced in this code.
This code is based on current knowledge and construction methods within the industry and is
not intended to exclude other methods or processes that can be shown to meet the
requirements of providing a safe workplace.
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 Part
1
General

1.1
1.2
C O N T E N T S

PAGE
Purpose..................................................................... 9
Scope .........................................................................9
1.3 Regulations ............................................................... 9
1.3.1 Notification to WorkSafe Western Australia
Commissioner................................................... 9
1.3.2 Documents on site........................................... 9
1.3.3 Workplan ........................................................ 10
1.4 Relationship to Australian Standards ..................... 10
1.5 Referenced documents and further reading........... 10
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 General
1.1 Purpose For concrete panels cast on-site it is the
builder’s responsibility to ensure
The purpose of this code is to provide notification requirements are met. For
practical guidance on the design and concrete panels cast off-site this
construction of structures using concrete wall responsibility rests with the employer or
panels and other precast concrete elements; self employed person who is also
to ensure, as far as is practicable, a safe required to provide a copy of the notice
working environment for those in the industry. to the builder.
The notification is made by completing a
1.2 Scope form available from WorkSafe and
provided to the Commissioner at least
The code covers the safe design, 10 working days before casting of the
manufacture, transport, cranage, storage, concrete panels is intended to begin.
erection and stabilisation of:
The notification must provide the
• concrete wall panels, whether precast on Commissioner with the following
or off-site, and their use in the building information:
and construction industry; and
• the construction site or other
• other precast concrete elements and workplace where the casting is to
their use in the building and take place; and
construction industry.
• the construction site where the
The Definitions of terms used in this code concrete panel is to be installed.
are contained in Appendix A.
1.3.2 Documents on site
Regulation 3.88G requires the following
1.3 Regulations Regulation 3.88G
documents be kept at the site at all
Regulations 3.88 to 3.88J apply to the times when tilt-up work is being carried
manufacture of concrete wall panels, out:
including retaining walls, whether precast
• a copy of the notification to the
on site or off-site, and to tilt-up work as
Commissioner referred to in section
defined.
1.3.1 above;
The regulations do not apply to other
• a copy of any exemption from the
precast concrete elements.
requirements of the regulations
However, this code of practice offers granted by the Commissioner under
practical guidance on complying with the Regulation 2.12, in relation to the
requirements of the regulations as well as work;
practical guidance on the safe use of other
• a copy of the shop drawings (see
precast concrete elements.
section 5.2.2);
1.3.1 Notification to WorkSafe Western • a current plan setting out details of
Australia Commissioner the proposed execution of the work
Regulation 3.88A The Commissioner must be notified of together with a copy of any related
the intention to manufacture concrete instructions or diagrams received
panels as defined. from an engineer by the builder (see
section 1.3.3); and
Regulation 3.88F No casting of concrete panels or tilt-up
work as defined (other than work • a copy of the inspection report of the Regulation 3.88B
relating to the manufacture of the formwork set-up referred to in AS
concrete panel prior to casting) may be 3850 section 4.10 (see section 6.7)
carried out without this notification. for each concrete panel.
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 Regulation 3.2 A copy of AS 3850 and this code of erected, or in its finished form, to
practice should also be available at safely transmit applied loads through
the site. the structure (see section 4.4 of this
code). Of critical importance is the
See section 6.7 regarding the
stability of the structure while roof
manufacturer’s statement and the need
members are being erected. See AS
for it to be available on site at the time
3828, Guidelines for the erection of
of lifting the concrete elements.
building steelwork;
A copy of the relevant local government
• traffic management plan (see section
building licence should be kept at the
7.4.6 of this code);
site.
• job safety analysis and risk
1.3.3 Workplan assessment (see section 2.4 of
Regulation 3.88G Regulation 3.88G requires that an up to this code); and
date plan that sets out details of the • signed copies of any changes made
proposed execution of the work be at to specifications and/or signed
the workplace whenever tilt-up work is instructions, advice or diagrams
carried out. made or issued by an engineer.
A copy of the workplan should be Information and guidance on these
lodged with the relevant local requirements may also be found in
government authority for filing with the AS 3850.
relevant building licence. The Department
of Local Government and Regional
Development intend to make this 1.4 Relationship to
lodgement a requirement of the Building Australian Standards
Regulations 1989. Information contained
in the workplan will greatly assist the Regulations 3.88 to 3.88J require, amongst
safety of any future demolition work. other things, that the design, manufacture,
transport, cranage, storage, erection and
The workplan should contain the stabilisation of concrete panels be carried
following information: out in accordance with the relevant parts of
• proposed sequence of work and AS 3850.
proposed work method statement This requirement underpins most of the
(see sections 8.2 and 8.3 of this information contained in this code.
code). Prior to manufacturing the
concrete elements, the complete This code is intended to complement
construction and erection sequences AS 3850 and other key Australian Standards
should have been planned; AS 3600, AS 3610 and AS 3828 dealing
with tilt-up and precast concrete structures.
• methods of stabilisation (temporary
and permanent) of the structure. The Other relevant Australian Standards are
method of stabilising the structure referenced in this code.
while concrete panels are being
erected needs to guard against
collapse of a panel and progressive 1.5 Referenced documents
collapse of the structure. The method and further reading
needs to ensure adequate structural
Appendix C provides a list of documents
strength and continuity of the
where further information may be obtained.
structure and its parts while being
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Part2
Training, supervision
and hazard management
C O N T E N T S

PAGE
2.1 General .....................................................................12
2.2 Training and supervision ........................................ 12
2.3 Safety and health.................................................... 13
2.4 Hazard management ............................................... 13

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 Training, supervision
and hazard management
2.1 General 2.2 Training and supervision
A principal objective of Western Australia’s Employees need to work safely. They
Occupational Safety and Health Act 1984 is should be trained and instructed in safe
to promote safe working environments and systems of work and safe work practices.
to prevent harm to employees at work. To Regulation 3.88I
The builder must ensure that the
do this, it imposes duties of care on and 3.88J
manufacture of concrete panels and other
employers, employees, and others, and
tilt-up work is directly supervised by a
requires employers and employees to co-
person who has completed an approved
operate in ensuring that workplaces and
training course for managers and
work practices are safe and without risks to
supervisors in the construction industry
health.
regarding the manufacture of concrete
One of the employer's primary duties under panels or other tilt-up work as appropriate.
the Act is to provide:
Approved training course means a training
The Act, “such information, instruction, and training course approved by the WorkSafe Western
section 19 (1)(b)
to, and supervision of, his employees as is Australia Commissioner.
necessary to enable them to perform their
Direct supervision means oversighting the
work in such a manner that they are not
work while it is being carried out having
exposed to hazards.”
regard to ensuring by way of direction,
Employers owe this same duty of care to demonstration, monitoring and checking
independent contractors and the that the work is being performed in a safe
contractor’s employees working at the manner in accordance with agreed
workplace. The Commission for procedures (the work plan) and ensuring a
Occupational Safety and Health Guidance capacity to respond immediately in an
Note General Duty of Care in Western emergency.
Australian Workplaces provides detailed Regulation 3.88I
The builder must also ensure that all
information on the duty of care. and 3.88J
personnel involved in the manufacture of
In fulfilling this obligation, there should be concrete panels or other tilt-up work have
a structured system of education and completed an approved training course
training to enable both employers and concerning the aspect of the work in which
employees to: the person is involved.
• identify and manage the risks involved Training programs should include:
in the manufacture, transport, cranage,
• induction on this code and AS 3850;
storage, erection and stabilisation of
concrete panels and precast concrete • first aid training to the minimum
elements; and requirements of the Commission for
Occupational Safety and Health Code of
• keep abreast of the current state of
Practice for First Aid Facilities and
knowledge within the industry on the
Services;
means of eliminating hazards and
controlling risks to safety and health. • identification of hazards associated with
the use of plant and equipment; and
• the selection, fitting, care, use and
storage of protective clothing and
equipment.
page

12
All personnel directly undertaking casting, Employers should inform employees of the
transport, cranage, storage, erection and results of any safety and health monitoring
stabilisation of panels will be undertaking tilt- carried out in the workplace.
up work. Other personnel working on a site
Employers, so far as practicable, are also The Act, section 21
while casting of panels through to permanent
responsible for the safety and health of
stabilisation is being carried out may also be
people who are not employees. Employers
undertaking tilt-up work as defined.
need to take all practicable steps to ensure
A risk assessment should be carried out to that the work of the employer or employees
determine which of these other personnel, does not harm any other person while at
and any visitors to the site, require training, work, including members of the public or
and the extent of this training. visitors to the workplace.
Employees are responsible for their own The Act, section 20
safety and health while at work and should
2.3 Safety and health take reasonable care to ensure that their
Employers should ensure that all employees actions do not harm or place others at risk.
have the opportunity to be fully involved in One of their obligations is to co-operate
the development of procedures including with their employer on safety and health
hazard identification, assessment of risk matters and not to interfere with or misuse
and methods used to control the risk. anything provided by their employer to
protect safety and health.
In particular, they need to take all
practicable steps to:
• provide and maintain a safe working 2.4 Hazard management
environment;
Employers need to have in place an
• provide and maintain facilities for the effective method to identify hazards and to
safety and health of employees; determine whether there are significant
• ensure that machinery and equipment is hazards that require further action. A hazard
designed, manufactured, set up and is an existing, new, or potential situation or
maintained to be safe for employees; event that could result in injury or harm to
health.
• ensure that employees are protected
from hazards in the course of their work; In the tilt-up and precast concrete industry,
risk is always present when handling,
• provide procedures to deal with transporting and erecting concrete
emergencies that may arise while elements. Although failure of material,
employees are at work; and components or equipment is rare the
• consult and co-operate with safety and consequences are always significant.
health representatives, if any, and other To ensure appropriate hazard management,
employees at the workplace regarding an identification of the hazards and an
safety and health at that workplace. assessment of the risks from these hazards
Before commencing work on a project, should be carried out by the builder in
employees should be informed by their conjunction with the safety and health
employer of: representatives of the contractors and
workers involved in the work.
• hazards they may be exposed to while
at work; A job safety analysis that lists the hazards
and suggests safety procedures should be
• hazards they may create while at work prepared. The minimum requirements for
that could harm other people; this job safety analysis include:
• how to minimise the likelihood of • an identification of the hazards;
hazards becoming a source of harm to
themselves and others; • an assessment of the risks from the
hazards identified;
• the location and correct use of safety
equipment; and • control measures required to eliminate or
minimise the risks from the hazards; and
• emergency procedures.
page

13
 • identification of the person responsible and work instructions, use of protective
for implementing and monitoring the equipment, and posting of warning signs
control measures. should be implemented. Such measures
should be discussed with employees and
Where possible, the hazard should be
evaluated to ensure that they are effective
eliminated or the risk reduced by changing
and do not create additional hazards.
or modifying the proposed work method or
construction method, or by use of The accepted means of planning to prevent
alternative equipment. injury is to identify hazards and then assess
and control the risk. At the control stage
Where the hazard cannot be eliminated,
there is a recognised hierarchy of hazard
control measures should be implemented to
control measures that should be applied.
isolate the hazard and to minimise risk to
These processes for managing risk should
employees. In these circumstances,
be followed as part of the hazard
measures such as barricading areas of
management process.
danger, provision of specific safety training
page

14
Part 3
Materials, components
and equipment
C O N T E N T S

PAGE
3.1 General – compatibility of components ................. 16
3.2 Concrete and reinforcement specifications............. 16
3.3 Curing compounds and release agents .................. 16
3.4 Lifting, bracing and fixing inserts........................... 17
3.4.1 General......................................................... 17
3.4.2 Lifting inserts ............................................... 17
3.4.3 Bracing inserts ............................................. 17
3.4.4 Fixing inserts................................................ 17
3.4.5 Anchors ........................................................ 18
3.5 Re-usable lifting equipment.................................... 18
3.5.1 Strongbacks ................................................. 18
3.5.2 Lifting clutches............................................. 19
3.6 Braces and props.................................................... 19
3.7 Levelling pads and shims ....................................... 19
3.8 Crane and rigging equipment ................................. 19
3.9 Proprietary documentation..................................... 20
page

15
 Materials, components
and equipment
3.1 General – compatibility Consideration should be given to the
following factors:
of components
• solubility - the product should not be
All materials, components and equipment
able to be washed off by rain;
should comply with the relevant Australian
Standards, in particular the requirements of • temperature effects – exposure to
AS 3850. extreme temperatures should not blister
the product and cause it to lose its
All components used on site within a
properties;
particular system should be compatible and
different proprietary components should not • compatibility with finishes - the
be mixed without verification of adherence of applied finishes, including
compatibility. Verification of compatibility joint sealants, should not be affected by
should be obtained from suppliers and the the curing compound and release
designer of any other equipment to be agents; and
used. • discolouration - if it is a pigmented
Incompatibility of different types of inserts product, the pigmentation should
or sizes may lead to failure. This is weather off within a reasonable time.
particularly relevant to lifting inserts, bolts, If any curing compound or release agent or
ferrules and lifting clutches. proprietary combination product is a
hazardous substance in accordance with
regulation 5.3, a Material Safety Data Sheet Regulation 5.3
3.2 Concrete and (MSDS) must be supplied by the
reinforcement specifications manufacturer and made available to all
The strength of the concrete at initial lifting workers who may be exposed to the
and for the in-service condition should not substance. The builder must consult with all
be less than the value specified on the workers who might be exposed to the
shop drawings. substance about the intention to use the
substance and the safest method of use.
Testing of concrete and verification of Workers likely to be exposed must receive
concrete strength should be determined in training on health risks, control measures
accordance with the requirements of the and correct use in accordance with
appropriate parts of AS 3600 and AS 1012. regulation 5.21. They must also be informed Regulation 5.21
about the need for, and details of, health
surveillance.
3.3 Curing compounds and
Part 5 of the Occupational Safety and
release agents Health Regulations 1996 provides further
Before a release agent is chosen for use in information on the responsibilities of
the manufacture of a concrete element, it persons who manufacture or supply
should be checked for compatibility with hazardous substances and those who are
the curing compound and other applied responsible for their use at workplaces.
finishes and joint sealants. A proven
The strength, watertightness and durability
proprietary combination curing
of concrete depends on the concrete being
compound/release agent can be used.
adequately cured. Curing compounds and
Specialist advice may be necessary from the
release agents should comply with AS 3799.
manufacturer or supplier of the product or
products used.
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16
3.4 Lifting, bracing and should not be used in any part of an
insert anchorage.
fixing inserts
3.4.3 Bracing inserts
3.4.1 General
Bracing inserts within a concrete panel
Lifting, bracing and fixing inserts should
should be cast-in products where
comply with the requirements of AS 3850.
possible. Where cast-in inserts are found
All lifting, bracing and fixing inserts to be unusable after casting, approval
should be manufactured from ductile should be obtained from the erection
materials and site welding of design engineer to use an alternative
reinforcement to inserts (other than weld type prior to installation.
plates) should not be carried out.
Bracing inserts should be designed,
Product documentation for proprietary manufactured and installed to provide a
inserts should be provided by the WLL with a limit state factor of at least
supplier, available on site and include 2.5 against concrete failure. In
full technical specifications, make, type determining this, the applied load needs
and working load limit (WLL). to include all expected loads including
construction loads and wind loads.
If non-proprietary inserts are used they
should be designed in accordance with Where cast-in bracing inserts are not
the appropriate Australian Standard by used in brace footings, an acceptable
an engineer to be compatible with the alternative is the use of drilled through
other parts of the system with which fixings, undercut anchors or load
they are to be used. controlled expansion anchors.
The type and capacity of lifting, bracing
3.4.4 Fixing inserts
and fixing inserts should be specified on
the shop drawings. They should not be Fixing inserts for the panel connection to
changed without prior approval of the roof framing and other structural
erection design engineer. members should be designed in
accordance with the appropriate
3.4.2 Lifting inserts Australian Standard and the Building
Code of Australia (BCA) to resist the
Lifting inserts within a concrete panel
forces imposed on the connections.
should be specified as cast-in products.
Where cast-in inserts are found to be Cast-in fixings such as threaded inserts,
unusable after casting, approval should weld plates or brackets should be used
be obtained from the erection design where possible. They need to be fully
engineer to use an alternative type prior anchored to transfer load into the
to installation. concrete.
Lifting inserts should be designed, Anchorage and load transfer for
manufactured and installed to provide a threaded inserts is achieved by a
WLL with a limit state factor of at least crossbar fitted through a cross-hole
2.5 against concrete failure. In determining (see Figure 3.1).
This illustration has
this, the applied load needs to include been reproduced
the mass of the element as well as pth from the Tilt-up
n de ailure Construction Notes
suction and impact load due to lifting. sig e f
De con T50, 1997 with
for permission of
Prestressing strand is not suitable as Cement Concrete &
lifting inserts and should not be used. Aggregates Australia
The strand may bend and weaken at the
point of exit from the concrete.
May have Internally threaded
Steel reinforcement bar is also not enlarged base cross-holed ferrule,
20 mm minimum
suitable as lifting loops and should not diameter
be used. Certain high tensile strength
steel bar has properties that make it Anchor bar
suitable only to resist tensile forces and
page

Figure 3.1: Threaded insert

17
 Where possible, fixings should be the brace itself requiring additional
standardised for all panels on an braces to support the panel. The use of
individual project to minimise the inserts with higher capacities may avoid
chance of error. this. As mentioned in section 9.1 of this
code there is difficulty in ensuring an
Where permanent fixings or connections
even load distribution where more than
are to be also utilised for temporary use
two braces are used.
during construction, the builder or the
erector should verify that such use will Figure 3.2: Load controlled expansion
not compromise their long-term anchors
performance.
Example of load controlled (torque
controlled) heavy duty safety anchors
3.4.5 Anchors
Expansion anchors are either load High strength
controlled or deformation controlled internal bolt
as defined in Appendix A. Only load
controlled (see Figure 3.2) are permitted
in tilt-up and precast concrete
Close fitting heavy
construction. Where these anchors are wall distance sleeve
This illustration has
used, the WLL should be limited to 0.65 been reproduced from
of the first slip load determined in the “Precast Concrete
accordance with AS 3850. Handbook” with
permission from the
Anchors used should be tested in Internally tapered National Precast
expansion joint Concrete Association
accordance with Appendix A3.2 of Australia.
AS 3850.
Deformation controlled expansion
anchors, including self drilling, drop in
and spring coil anchors should not be
used because they may fail without
warning, are highly sensitive to
installation procedures and have no
3.5 Re-usable lifting
additional load capacity after the initial
setting process. equipment
Expansion anchors should be 3.5.1 Strongbacks
manufactured from ductile material.
Concrete panels that are odd shaped,
Chemical anchors relying on chemical elongated or with large or awkwardly
adhesion should not be used because positioned openings may require the
they may fail without warning and are addition of steel strongbacks to enable
highly sensitive to installation them to be successfully lifted and
procedures. placed.
Expansion anchors are more susceptible Strongbacks may be used to strengthen
to installation errors than drilled-through the panels or to locate additional lifting
fixings. A calibrated torque wrench points to prevent out-of-plane rotation
should be used to ensure correct of odd-shaped panels.
installation torque is achieved when
Where strongbacks are used, their
installing expansion anchors, and special
weight needs to be included in the
attention needs to be given to the
calculation to determine the weight of
correct drilling of the holes.
the panel and its centre of gravity for
There needs to be an adequate checking lifting purposes.
system to ensure expansion anchors are
Strongback fixing inserts should be
installed correctly.
either cast-in ferrules or load controlled
With brace footings, the capacity of expansion anchors.
anchors may be less than the capacity of
page

18
 3.5.2 Lifting clutches (NATA) laboratory or equivalent. Braces
should be designed with a limit state factor
Lifting clutches should be designed with
of at least 2 against failure.
a limit state factor of 5. Lifting clutches
should be proof tested to a load of 2 Brace adjustment mechanisms should have
times the WLL, certified and individually stops on the threads to prevent over-
identified by permanent marking or extension and retaining devices to prevent
attachment of a durable tag prior to use. unintentional dislodgment of the shear pin.
The shear pin should be purpose made,
A proof test using a load equal to 1.2
simple to install and be constructed so that
times the WLL should be conducted and
it cannot be undone without the use of
recorded at least at 12 monthly periods.
appropriate equipment or the application of
deliberate force.
3.6 Braces and props The WLL for props should be supplied by
the manufacturer.
The safe erection of concrete panels and
precast concrete elements relies, to a large Brace and prop requirements and details for
extent, on the integrity of the braces and each type of concrete panel or precast
props used and their correct installation. concrete element should be clearly specified
on the shop drawings. Where applicable,
Bracing and propping systems should be
this includes requirements and details for
designed to resist all expected loads,
knee bracing and any other secondary
including:
bracing required.
• construction loads; and
Braces should never be used as props and
• wind loads for temporary structures in props should never be used as braces.
accordance with AS/NZS 1170.2.
Braces should have a permanently fixed
identification plate displaying the following 3.7 Levelling pads and shims
information: Levelling pads and shims should comply
• the supplier or manufacturer; and with the relevant requirements of AS 3850.

• the model type or designation. Unless designed and specified otherwise,

shimming should be a maximum height of
In addition, the load capacity of the braces 40 mm, a minimum length of 150 mm and a
should be marked as follows: minimum width of 100 mm.
• for fixed length braces, WLL, in
kilonewtons (kN), on the permanent
identification plate; 3.8 Crane and rigging
• for adjustable length (telescopic) braces,
equipment
the WLL, in kN, at maximum and at Crane charts should be used to determine
minimum extension, on the permanent the required crane capacity. The correct
identification plate; and selection of cranes, however, requires that
the configuration of the crane (its location
• for composite braces, the WLL, in kN, at
in relation to the lift) needs to be
maximum and at minimum extension,
considered as well as the actual load that is
and at intermediate positions, suitably
to be lifted. The actual load should include
and clearly marked on the brace.
the weight of the lifting gear, crane block
The WLL for braces at maximum and and rope and any strongbacks.
minimum extension should be determined
Cranes should be selected and operated in
in accordance with the requirements of AS
accordance with the appropriate parts of AS
3850, taking into account the forces and
2550.
eccentricities associated with the complete
assembly of components that comprise the All rigging equipment should comply with
brace. Where this involves testing, such the relevant Australian Standards and have
tests should be conducted by a registered a WLL adequate for its intended application.
National Association of Testing Authorities It should be in a serviceable condition.
page

19
 The selection of the rigging gear used • criteria for rejection and reworking of
during lifting and erection of concrete the component or system;
elements should ensure the rigging is not
• detailed information including, where
subjected to forces for which it has not
appropriate, the following:
been designed.
- part number;
Snatch blocks and other sheave blocks
need to be equipped with thrust races or - dimensions;
separate swivel bearings if rotation of - section properties;
sheave block swivels under load is
unavoidable. Blocks with standard plain - self-weight;
bearings are not intended to be rotated - details of any special attachments,
under load. eg coupling sleeves; and
- locations for attachment points and
3.9 Proprietary bracing points;

documentation • the strength and serviceability limit state

capacities;
Proprietary documentation should set out
the information required for the correct use • the WLL; and
of the component or system. It should • a statement that the component or
include the following information, where system depicted in the documentation
applicable: complies with AS 3850.
• drawings that clearly identify the Proprietary documentation should be readily
component or system to which it refers; available on site, if required. Full
• adequate information to fully describe documentation need not be held on site
its intended use; but should be obtainable within a
reasonably short period.
• instructions for use, storage and
maintenance, including all precautions to
be observed in its use;
page

20
Part 4
Design
C O N T E N T S

PAGE
4.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
4.2 Preplanning . . . . . . . . . . . . . . . . . . . . . . . . . 22
4.3 Design loads . . . . . . . . . . . . . . . . . . . . . . . . 22
4.3.1 General . . . . . . . . . . . . . . . . . . . . . . . 22
4.3.2 Suction loads . . . . . . . . . . . . . . . . . . . 23
4.3.3 Impact loads . . . . . . . . . . . . . . . . . . . . 23
4.3.4 Wind loads . . . . . . . . . . . . . . . . . . . . . 23
4.3.5 Erection loads . . . . . . . . . . . . . . . . . . . 23
4.4 Building stability . . . . . . . . . . . . . . . . . . . . . . 23
4.5 Structural design . . . . . . . . . . . . . . . . . . . . . . 24
4.5.1 General . . . . . . . . . . . . . . . . . . . . . . . 24
4.5.2 Fire . . . . . . . . . . . . . . . . . . . . . . . . . . 24
4.5.3 Design tolerances . . . . . . . . . . . . . . . . 25
4.6 Specification of concrete . . . . . . . . . . . . . . . . 25
4.7 Design for manufacture and erection . . . . . . . . 26
4.7.1 Design and manufacture . . . . . . . . . . . . 26
4.7.2 Additional reinforcement . . . . . . . . . . . . 26
4.7.3 Design for erection. . . . . . . . . . . . . . . . 26
4.8 Panel thickness. . . . . . . . . . . . . . . . . . . . . . . 29
4.9 Slenderness effects . . . . . . . . . . . . . . . . . . . . 29
4.9.1 Panel height to thickness ratio . . . . . . . 29
4.9.2 Dual lift slenderness design. . . . . . . . . . 29
4.10 Panel supports . . . . . . . . . . . . . . . . . . . . . . . 29
4.11 Fixing inserts . . . . . . . . . . . . . . . . . . . . . . . . 30
4.12 Joints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
4.13 Brace footings. . . . . . . . . . . . . . . . . . . . . . . . 31
4.13.1 General. . . . . . . . . . . . . . . . . . . . . . . . 31
4.13.2 Floor slabs . . . . . . . . . . . . . . . . . . . . . 31
4.13.3 Concrete blocks (deadman) . . . . . . . . . . 31
4.13.4 Other footings . . . . . . . . . . . . . . . . . . . 31
4.14 Connections . . ....................... 31
4.14.1 General. ....................... 31
4.14.2 Panel to panel . . . . . . . . . . . . . . . . . . . 31
4.14.3 Panel to footing or floor slab . . . . . . . . 33
4.14.4 Panel to structural steel . . . . . . . . . . . . 33
4.15 Strongbacks . . . . . . . . . . . . . . . . . . . . . . . . . 34
page

21
 Design
4.1 General The structural design should also give
consideration to the safety of any future
In tilt-up and precast concrete construction demolition of the building or structure.
there are two separate phases of design.
The first, the in-service or structural design,
is for the in-service condition and is usually 4.2 Preplanning
carried out by the project design engineer Preplanning and close co-ordination
as part of the design of the complete between the relevant parties is essential to
structure. The in-service design provides for ensure safety in the use of concrete panels
the performance of the concrete panel or and precast concrete elements.
precast concrete element as part of the
complete structure. The project design It is not possible to obtain the full benefit
engineer needs to be experienced in the and economies inherent in their use without
field of precast construction. preplanning and co-ordination between the
relevant parties.
The second, the design for erection, is for
the handling, transportation, erection and Prior to preparation of the shop drawings,
bracing of the individual concrete elements the parties involved in the design,
during the erection process. It may be manufacture, transport and erection process
carried out independently of the structural should liaise to plan the complete
design by the erection design engineer. construction and erection sequences.
During the braced condition the structure Consideration needs to be given to details
may be regarded as a temporary structure such as site limitations, local street access,
and particular care is required to minimise delivery sequence, transport requirements,
the risk of progressive collapse. cranage requirements and overhead
obstructions. These aspects can have a
The structural design should take into significant effect on the size of concrete
account the particular requirements of elements and on the erection process.
precast concrete structures to ensure that
the elements can be safely erected without The floor slab should be designed to cater
any component failure occurring. for all construction loads likely to occur,
such as from cranes and concrete trucks.
The Act, Important obligations under the Occupational
section 23(3a)
Safety and Health Act 1984 are placed on
those who design or construct any building 4.3 Design loads
or structure, including a temporary structure,
to have regard for persons who are to erect 4.3.1 General
or use the structure. Section 23 (3a) of the
As well as the in-service design,
Act states that:
concrete panels and precast concrete
“A person who designs or constructs elements need to be designed for the
any building or structure, including loads and conditions likely to be
a temporary structure, for use at a experienced during the manufacturing,
workplace shall, so far as is practicable lifting, transportation and erection
ensure that the design and construction phases.
of the building or structure is such that –
Consideration should be given to the
(a) persons who properly construct, following:
maintain, repair or service the
• handling loads;
building or structure; and
• storage and transport loads where
(b) persons who properly use the
applicable;
building or structure,
• erection loads;
are not, in doing so, exposed to hazards.”
page

22
• construction loads including any concrete panel from the casting bed. The
backfill and surcharge loads; increase in design loads due to suction
and impact is not cumulative.
• permanent, imposed and other loads
in accordance with AS/NZS 1170.1;
4.3.4 Wind loads
• wind load in accordance with
Wind loading on concrete panels will
AS/NZS 1170.2 on the braced
vary depending on the size of the
elements; and
panels, wind speed and wind direction.
• seismic load in accordance with In built-up areas the wind effect may be
AS/NZS 1170.4. less than in open areas although
“funnelling” effects can increase wind
The increase in design loads due to
loading in built up areas.
wind load and seismic load is not
cumulative. In cyclone prone areas of the State the
potential wind loading applied to panels
The effect of suction and adhesion at
will be greater. Sudden and severe wind
separation from the form or casting bed
gusts frequently occur throughout the
(lift-off) and dynamic and impact loading
State particularly in coastal areas.
during transportation, erection and
bracing should also be considered. Generally wind loading varies directly to
the square of the wind speed and small
4.3.2 Suction loads increases in wind speed will result in
Suction loads are reduced by use of an much higher loadings. This may result in
appropriate release agent (see section the need for more braces to be provided
3.3 of this code) and will vary according or a larger brace footing.
to the finish of the concrete panel and
4.3.5 Erection loads
the type of form or casting bed.
Recommended minimum values are: Concrete panels and precast concrete
elements need to be designed for the
• for concrete cast onto a steel bed, a
loads and conditions likely to be
20% increase should be applied to
experienced during the manufacturing,
the dead load;
lifting, transportation, erection, braced
• when casting concrete onto concrete and in-service phases in accordance with
casting beds, a 50% increase should AS 3850 and AS 3600.
be applied to the dead load; and
Erection load design should consider
• where the casting bed has a profiled variations to the load-distribution on the
or textured surface the "suction" load concrete elements during lifting, rotation
may exceed 100% of the dead load. and impact during placement.
Consideration should be given to the
casting bed profile to ensure that
adequate draw (slope) is provided to the 4.4 Building stability
fixed edges of the form not struck prior It is the responsibility of the builder to
to lifting. A minimum draw of 1:12 is ensure the stability of the structure during
recommended. the erection phase.

4.3.3 Impact loads The stability of the building for the in-
service condition is the responsibility of the
Impact loads generated during handling project design engineer.
and transport can be significant and
need to be considered in the design of The stability of the whole building should
the lifting inserts and rigging systems. be checked for each stage during erection
These increases may range from 20% and under in-service load conditions.
during handling by crane to up to 100% Special care needs to be taken in design
during transportation. and construction to guard against
progressive collapse both during
Impact loading should only be construction and in the completed structure.
considered after release (lift-off) of the
page

23
 Tilt-up concrete structures are susceptible erection design engineer should consider
to progressive collapse type failures. The them during the erection phase of the
failure of a single member such as a roof structure.
bracing member due to an event such as
Structural members supporting concrete
fire, accident or other cause, should not
elements should be designed to allow
lead to the complete collapse of the
for the situation where the concrete
structure. Consideration also needs to be
element bears on only two discrete
given to the situation during construction
shimming points during erection. The
when the dislodgement of a single concrete
erection sequence of concrete panels
panel could lead to progressive collapse.
can produce more adverse loading
Progressive collapse may be prevented by conditions in a supporting member than
providing either: the final in-service loads.
• adequate structural strength and
4.5.2 Fire
continuity of the structure and its parts;
or The Building Code of Australia (BCA)
sets out the requirements for the design
• alternative load paths that cause applied
of buildings against fire. It specifies the
forces to be safely transmitted through
fire resistance level (FRL) for various
the structure.
building elements. The FRL depends on
Structural continuity may rely upon, among the type of construction, determined for
other things, moment, shear or tensile the occupancy class of building and
connections, depending on the kind of height in stories, and proximity to the
structural system employed. fire source. The FRL gives the fire
resistance periods (FRP) for structural
The workplan referred to in section 1.3.3 of
adequacy, integrity and insulation. AS
this code includes documented methods of
3600 provides methods for determining
stabilisation, both temporary and permanent,
the FRP of concrete members. Concrete
of the structure. In considering methods of
panels should comply with these
stabilisation, the requirements of AS 3828
requirements. AS 4100 provides periods
should be taken into account.
of structural adequacy for the steel
elements of the building.
4.5 Structural design Joints between the panels should also
satisfy the appropriate FRP and not
4.5.1 General adversely affect the behaviour of the wall.
The structural design of the concrete In addition to setting out the
elements should be carried out in requirements for the design of buildings
accordance with the requirements of AS against fire, the BCA also sets out
3850 and AS 3600, as appropriate, and requirements for the performance of
the provisions of this code. buildings subject to fire. These
See section 8.14 of this code regarding requirements are set out in Part C 1.11,
approvals necessary for modifications to Performance of external walls in a fire.
any concrete elements, including the To comply, the concrete panel design
design. will require connection details such that
the panels during and after a fire will
Slenderness and stability are major either remain standing or tend to
considerations in the design of concrete collapse inwards.
elements. Precast concrete construction
may lack the continuity inherent in cast Detailed information on the design of
in-situ concrete structures. The building lightly loaded wall panels is available in
designer and project design engineer Recommended Practice, Design of Tilt-up
need to address these issues for the in- Concrete Wall Panels referenced in
service condition while the builder and Appendix C.
page

24
4.5.3 Design tolerances 4.6 Specification of concrete
Because concrete elements cannot be The concrete specification should be clearly
manufactured to exact dimensions, shown on the shop drawings and include
provision needs to be made in the any special requirements, eg slump,
design for dimensional variation in maximum size aggregate, cement content,
accordance with the appropriate water-cement ratio and colour.
Australian Standard.
The specification of the strength of concrete
For concrete panels the standard is AS needs to take into account the flexural
3850. For other precast concrete strength required to develop insert strength
elements the standard is AS 3600. at lifting as well as the requirements for in-
Figure 4.1 shows recommended service loading, durability and ease of
tolerances on as-cast concrete panels construction.
and insert location.

PANELS

Tolerance (mm)

Panel
Height (m) Linear Angular Profile

Width Height Thickness Squareness Twist Warp Straightness of edges

(Note 1) (Note 2) (Note 3) and flatness of surfaces

<3 +0,-6 ±3 ±3 ±4 ±3 ±3 ± Length/1000

≥3 < 6 +0,-6 ±6 ±3 ±5 ±3 ±3 ± Length/1000
≥ 6 < 10 +0,-6 ±6 ±3 ±6 ±3 ±3 ± Length/1000
≥ 10 +0,-6 ±6 ±3 ±8 ±3 ±3 ± Length/1000

Figure 4.1: Recommended tolerances

NOTES:
The concrete strength required at lifting
1 Expressed in terms of the distance by which a
shorter side of the concrete panel deviates from a should be in accordance with the erection
straight line perpendicular to the longer side and design engineer’s specifications. Some
passing through the corner of the unit.
2 Per metre width in 3m length. guidance on the early-age strength of
3 Per metre width. normal-class concrete is given in AS 1379.
To obtain adequate concrete strength for
early lifting it may be necessary to specify
INSERT LOCATION
28-day concrete strengths of 32 MPa or
Type of insert Tolerance (mm)
higher, which should develop a strength of
Face lifting ± 20 25 MPa at 7 days, the minimum concrete
Bracing ± 50 strength for most proprietary brand lifting
Strongback ±5 inserts to achieve the required limit state
Edge-lifting factor of 2.5 during lifting. Higher strength
longitudinal ± 20 concrete may be used to enable concrete
thickness ±5
panels to be lifted earlier than 7 days.

Fixing ±5 Verification of concrete strength should be

carried out by testing in accordance with AS
3600 and AS 1012.
Where required tolerances are less than
the recommended values, the specific
requirements should be clearly stated on
the shop drawings.
page

25
 4.7 Design for manufacture 4.7.3 Design for erection

and erection When fixed length multi-legged slings

are to be used for lifting concrete
4.7.1 Design and manufacture elements, any two of the lifting inserts
should be capable of supporting the
In determining the size and shape of
total load.
concrete elements, consideration should
be given to: The load capacity of lifting inserts is
dependent on several factors including:
• whether concrete elements are to be
cast on-site or off-site; • the concrete strength of the concrete
element at the time of lifting;
• size, capacity and configuration of
crane(s) available to undertake lifting • embedment depth of the insert; and
and erection;
• direction of load, shear or tension
• location and proximity of overhead (see Figure 4.2).
power supplies; Direction of load
before rotation
Concrete panel
• access to and around the site;
• bracing and propping requirements;
and
• transport restrictions.
Where concrete elements are to be cast
off-site, consideration should be given to Edge lifter
limiting one dimension so that the
element can be transported without the
need for a pilot or special permit. Concrete panel
SHEAR LOAD

4.7.2 Additional reinforcement

Direction of load
Additional reinforcement may be required after rotation
in concrete panels and precast concrete
elements to accommodate forces during
handling, transportation and erection.
Additional reinforcement or strongbacks
should be provided where the maximum
flexural tensile stress in a concrete panel Edge lifter
exceeds the limits recommended in AS TENSION LOAD
3850.
Figure 4.2: Shear loads and tension
For concrete panels additional
loads in edge-lifted concrete panels
reinforcement may be required:
• near the base of the panel to resist
stresses arising from thermal and When selecting a lifting insert, ensure
shrinkage movements whilst the that the nominated capacity from the
panel is supported only on the manufacturer’s catalogue is for the
levelling shims; directions of the load being applied.
• at edges and around openings in the All lifting inserts require adequate
panel to resist thermal and shrinkage embedment or anchorage to function
stresses and to prevent cracking due effectively. Anchorage is affected by:
to panel mishandling; and • proximity to edges;
• where there is a possibility of load • proximity to holes, recesses or edge
reversal due to mishandling during rebates;
transport or erection.
page

26
• proximity to other loaded lifting Where this is the case, such
devices; requirements should be clearly specified
on the shop drawings.
• concrete thickness;
To prevent the concrete panel slewing
• concrete strength at lifting;
sideways during erection, lifting inserts
• embedment depth; should be located symmetrically about
• the presence of cracks; and the centre of gravity across the width of
the panel. In determining the centre of
• the proximity of reinforcement or gravity, the effect of any additional
prestressing tendons. equipment such as strongbacks needs to
Horizontal bars placed around the foot be taken into account. When the panel
of a lifting insert may provide very little is lifted, the bottom edge should be
additional lifting capacity to the insert. horizontal.

Lifting inserts should be configured in Lifting inserts may be positioned in the

accordance with the manufacturer’s face or edges of a concrete panel. The
recommendations, including component actual locations of the lifting inserts is
reinforcement requirements. determined according to the:

The number of lifting inserts required is • method of lifting (face or edge);

dependent on several factors including • mass, size and shape of the concrete
the concrete element size and shape, element and presence of openings
insert capacity and insert location. The and cut-outs;
location of lifting inserts is interrelated
with the reinforcement design and the • structural capacity of the concrete
proposed erection procedures. element;

When locating lifting inserts, consideration • concrete strength at the time of

needs to be given to the need for lifting; and
strongbacks if the concrete element has • capacity of the lifting inserts.
large or awkwardly located openings.
When it is intended that concrete panels
Multiples of three rows or columns of be tilted about an edge using anchors
lifting points where equal loading is placed in the panel face, the geometric
required should be avoided because of centre of the face-lift inserts must be
the complex rigging configurations above the panel's centre of gravity.
required. For example, lifting
Face-lifted panels should be designed to
arrangements comprising 3, 6, 9 or 12
hang no more than 100 from the vertical.
lifting points should be avoided.
If this is not possible, consideration
Preferred lifting insert configurations for
should be given to using edge-lifting or
concrete panels are shown in Figure 4.3.
a combination of face-lifting and edge-
Although loads in the slings attached to lifting.
each insert in Figure 4.3 are equal, the
Bracing inserts should be located to
loads on the inserts may not be equal
allow the braces to hang vertically
for face-lifted concrete panels because of
without interfering with the lifting
the varying inclination of the slings to
rigging. A horizontal displacement of
the panel which also varies during
200mm for the bracing insert from the
rotation of the panel.
vertical line of the lifting inserts will
In general, the rigging system should be normally be adequate.
designed to distribute equal loads to all
Bracing inserts should not be located
lifting points. In some circumstances the
closer than 300mm to the edge of a
design may require unequal loading on
panel, footing or other bracing support.
lifting points causing an increased load
to be applied to particular lifting inserts.
This needs to be taken into account in
selecting the capacity of these inserts.
page

27
This illustration
has been
reproduced with
permission from
SAI Global

Figure 4.3: Preferred concrete panel rigging configurations

page

28
 Figure 4.4: Panel rotation

m
mu
m axi Rigging to
ed 60
nd main hoist
m me ess:
co k n
Rigging to Re /thic
n
tailing hoist spa

Th
ick
ne
ss

Concrete panel

4.8 Panel thickness 4.9.2 Dual lift slenderness design

The thickness of a concrete panel needs to Buckling and instability can occur during
be adequate to: lifting and erection of long slender
concrete elements.
• carry the design loadings;
Lifting inserts should be located to
• limit the lateral deflection of the panel ensure that compression flange buckling
to 1/250 of the panel span under (as in a long slender beam) cannot
serviceability loadings as required by AS occur particularly during rotation of
3850; and concrete panels.
• meet the minimum thickness required by The span/thickness ratio of the concrete
AS 3600 for the specified fire resistance element between lifting points should be
level (FRL ) where the panel is required limited to a maximum of 60 (see Figure
to have a fire resistance. 4.4) unless a detailed buckling analysis
is undertaken.

4.9 Slenderness effects

4.10 Panel supports
4.9.1 Panel height to thickness ratio
Concrete panels should be designed to sit
Panel height to thickness ratios are on only two localized shimming points
specified in AS 3600. These ratios may when initially erected. The panel and the
be exceeded provided a detailed footings should be designed to carry the
analysis is carried out taking into forces from the localized supports, taking
account the following factors: into account normal construction tolerances.
• loading on the panel; By specifying the locations of only two
• moments due to the eccentricity of shimming positions beneath a panel, the
vertical loads; designer can control where the weight of
the panel is supported. Construction
• moments due to deflection of the
tolerances are usually such that multiple
panel and its supports; and
shimming will not distribute the panel
• long term effects, if any. weight to its support in a predictable
page

29
 manner, since any two of the shims are Extreme heat, such as occurs during a fire,
likely to support most of the load. After reduces the capacity of fixing inserts and
erecting the panel, grouting beneath the other critical components. Drilled-in inserts
panel may serve to redistribute load may suffer a greater strength loss due to
following settlement beneath the original exposure to fire than cast-in inserts. Fixings
shimming points or additional loading of may have to be protected against fire if
the panel. heat will adversely affect their performance.
Drilled-in inserts may be used for fire
Where two panels land on a discrete
situations provided their performance can
support, the load eccentricities that occur
be substantiated.
during construction, because one panel has
to be erected before the other, can Care should be taken to ensure that
sometimes be a critical load case in design. secondary effects, for example eccentricity
of the steelwork framing cleat and semi-
See section 9.3 of this code for further
rigid rafter connections, are determined and
information on shims.
considered in the selection of fixing inserts.

4.11 Fixing inserts

4.12 Joints
The design of fixing inserts for connecting
Joint widths (gaps) between adjacent
panels to roof framing, and other structural
concrete elements should be sufficient to
members, should comply with AS 3850 and
maintain designed position and alignment
provide for the following:
during erection and accommodate
• the number, location and placement of tolerances and expected movements.
fixing inserts, adequate to resist the
Unless otherwise specified, joint widths
tension and shear forces (static and
between adjacent concrete elements should
cyclic) imposed on the connections;
not be less than:
• the reduction of insert capacity when
• 15 mm for joints with flexible sealant;
placed near an edge or an opening;
• 20 mm for mortar or grouted joints; and
• component reinforcement;
• 150 mm for in-situ concrete infills.
• adequate cover to all inserts; and
Special care should be taken when
• ductile behaviour and robustness of the
specifying minimum joint width as the panel
steel insert.
location tolerance, width dimension tolerance
The type and characteristics of fixing inserts and squareness tolerance may significantly
should be as specified on the shop reduce joint widths and affect the choice of
drawings and should not be changed joint sealant and its performance.
without prior approval from the project
When selecting joint filling materials,
design engineer.
consideration needs to be given to:
Fixing capacities are reduced when fixings
• thermal and shrinkage movement of the
are placed in near proximity to each other
concrete element;
or near edges and openings. Consideration
should therefore be given to the effects of • fire resistance level;
interference with other fixtures, fittings and
• weather resistance;
proximity of openings and edges. In these
cases, consideration should be given to • structural movements to be
providing additional reinforcement or other accommodated;
means to prevent failure and to resist • dimensional tolerances of panels; and
separation of the connection.
• panel location tolerance.
page

30
4.13 Brace footings A sketch of the brace footing should be
provided to the erector by the builder
4.13.1 General before erection commences. The sketch
should be signed by the erection design
The ends of braces should be fixed to a engineer.
solid, flat concrete or other surface that
is capable of resisting the applied loads. In calculating the capacity of the brace
footing, the direction of the applied
Brace footings need to be designed to brace loads, both in compression and in
resist all expected loads, including: tension, needs to be taken into account
• construction loads; and to ensure stability under all conditions.
Combined vertical and sliding mode
• wind loads for temporary structures
failure needs to be considered.
in accordance with AS/NZS1170.2.
Concrete block brace footings cast in the
Combinations of applied loads should
ground will need a larger mass in sandy
comply with AS/NZS 1170.0.
soils compared to stiff clays which have
Requirements and details of brace better cohesive properties and are better
footings for each type of concrete able to resist pull out loads.
element should be clearly specified on
the shop drawings. This should include 4.13.4 Other footings
the required concrete strength of the Other types of footings may be used
footing at the time of installation of the providing they are designed to ensure
bracing. sufficient capacity to resist the forces
from the braces. For example, concrete
4.13.2 Floor slabs
piles may be used as footing
Floor slabs are frequently sufficient for
brace footings, however it is unlikely
that floor slabs less than 100mm thick 4.14 Connections
will provide adequate fixing for braces.
It should not be assumed that a slab 4.14.1 General
greater than 100mm thickness will Concrete elements should be incorporated
always be adequate. into the structure in such a manner that
Braces should not be fixed closer than the risk of progressive collapse is
600mm from a joint in the slab. eliminated.
Connections should be specified and
4.13.3 Concrete blocks (deadman)
detailed on the shop drawings.
Where floor slabs are not capable of
A selection of typical panel connections
resisting the bracing forces, or are not in
for various situations is shown at Figure
place, concrete blocks (deadman) may
4.5.
be necessary to use as brace footings.
Impact driven fixings, including explosive
Unless specifically designated otherwise,
charge driven fixings, should not be used.
the concrete strength of the brace
footing at the time of installation of the 4.14.2 Panel to panel
bracing should be at least 25 MPa.
Brace footings are frequently cast using Connections between concrete panels
low strength concrete and will need to should allow for independent shrinkage
be left for longer to ensure anchors do and thermal movement between panels
not pull out. The specification of early and allow for construction tolerances in
age strength concrete may be necessary. locating fixing ferrules and other cast-in
components.
page

31
 Angle bolted to anchored
ferrules cast in the panels Metal capping, packed to a
minimum 1 in 4 inward stope

Panel vertical joint seal carried

across top of panel

Filler (fire-rated if required)

Roof
Pocket formed in panel and
later filled with grout. Angle
may be surface-mounted Roof flashing
depending on fire requirements

Parapet detail

Sealant and backing rod Sealant and backing rod

Angle bolted to
Filler (fire-rated if required) cast-in inserts

T-connector plate with For maximum tolerance,

elongated holes, bolted connecting angle should
to ferrules cast in top have horizontal and
edge of wall panels vertical slotted holes

Panel to panel at T-junction Panel to panel at external corner

Parapet detail

Roof truss with angle seat Purlin seat

Member of horizontal Member of horizontal

wind-load truss welded wind-load truss welded
or bolted to panels or bolted to panels to
(roof truss seat uses transfer lateral loads
similar connection) to end walls
This illustration has
been reproduced
from the Tilt-up
Construction Notes
T50, 1997 with
permission of
AT SIDE WALLS AT END WALLS Cement Concrete &
Panel to roof truss Aggregates Australia

Figure 4.5: Various typical panel connections

page

32
 Continuous recess with roughened
surface for bond (may be eliminated
Dowel holes in panel filled with if tie-bars designed to carry shear)
flowable grout as well as recess
between panel and slab edge Threaded tie-bars screwed into
ferrules cast in wall panel

Panel placed and levelled on

shims before fully bedding
on dry-pack mortar
Hole drilled and dowel epoxy-grouted
in place (This permits accurate setting-
out after slab and footing is cast) Concrete or steel permanent formwork

Bearing pad (50-mm wide typical)

Sealant
Panel to footing slab Panel to supended insitu concrete floor

Panel placed and levelled on shims

and temporarilly held by bolting Concrete topping to precast units
through angle into cast-in ferrule, if required
or by ‘blocking’
Precast concrete floor units
Threaded bars are screwed into
ferrules cast in panel, prior to
placing floor stabs, as final fixing

Bearing pad (70-mm wide typical)

Angle fixed to footing with
expanding anchor.
(Alternatively, panel may be Continuous-angle seat, site-welded to
‘blocked’ on either side) plates cast in wall panel
This illustration has
been reproduced
Panel to strip/pad footing Panel to suspended precast concrete floor from the Tilt-up
Construction Notes
T50, 1997 with
Figure 4.5: Various typical panel connections (continued) permission of
Cement Concrete &
In assessing the requirements for 4.14.4 Panel to structural steel Aggregates Australia
connections between panels,
Connections between concrete panels
consideration needs to be given to the
and other structural members, need to
effects of abnormal loads on the building,
be designed to resist the lateral and
such as vehicle impacts. For detailed
vertical forces imposed on the
information and recommendations on
connections in accordance with the
these issues, refer to the Precast Concrete
requirements of AS 3850 and AS 3600,
Handbook referenced in Appendix C.
as appropriate.
4.14.3 Panel to footing or floor slab The design of the connections needs to
take into account the capacity of both
A fixing system should be used to resist
the fixing and the concrete. The ultimate
horizontal load transmitted from
capacity should be the lesser of fixing
concrete panels into footings or floor
failure in tension and/or shear, or
slabs. The fixings should be capable of
concrete cone failure.
resisting the forces set out in AS 3850.
Friction forces should not be assumed to The project design engineer should
resist any part of this force. make allowance in the design of
connections between concrete panels
Grout tubes, particularly in the edges of
and steelwork for unexpected loads.
thin panels, should be provided with
These loads may result from:
restraining reinforcement on each side of
the tube. • erection problems due to panel
page

tolerance or fabrication issues;

33
 • steelwork collapse due to erection 4.15 Strongbacks
problems or crane collision; and
When strongbacks are required they should
• roof steelwork collapse due to fire. be designed to ensure the strongback is
The unexpected loads are generally sufficiently stiff to prevent cracking of the
additional tension loads, which tend to concrete panel due to differential deflection.
pull the panel and roof steelwork apart. The location of the strongbacks should not
The loads are generally not those loads interfere with the rigging at all angles of
identified as part of the structural panel rotation. See Figure 4.6 for examples
analysis. of strongback applications using steel
All concrete panel to steelwork channel section.
connections should be designed to The erection design engineer should
ensure a ductile failure. approve any changes to the specified
See section 9.2 of this code regarding strongback system prior to the changes
loads resulting from erection of being carried out and the shop drawings
steelwork. amended accordingly.

(a) Examples of strongback applications

This illustration
has been
reproduced with
permission from
SAI Global

(b) Steel strongback

Figure 4.6: Strongbacks

page

34
Part5
Documentation
C O N T E N T S

PAGE
5.1 Structural design drawings .................................... 36
5.2 Panel documentation ............................................. 36
5.2.1 Marking plan ............................................... 36
5.2.2 Shop drawings ............................................ 36
5.2.3 Erection documentation .............................. 37
5.3 Lodgement of shop drawings with
local government.................................................... 37

page

35
 Documentation
5.1 Structural design 5.2.1 Marking plan

drawings A marking plan (layout plan) prepared

by the shop detailer should show the
Structural design drawings and details are
location of each concrete element.
the responsibility of the project design
engineer and should provide sufficient 5.2.2 Shop drawings
information for the preparation of shop
drawings by the shop detailer and erection Shop drawings should provide all
documentation by the erection design information and details required to
engineer. manufacture the concrete element.

The information provided on structural The builder should check the shop
drawings should include: drawings for compliance with
dimensions of structural drawings.
• date and issue number of the drawing;
Standardised symbols should be used
• plans and elevations clearly indicating on the drawings in accordance with
the structural framing and concrete those used in AS 3850.
element layout;
Shop drawings should include the
• structurally critical dimensions; following:
• reinforcement and concrete cover • date and issue number of the
required for in-service loads and drawing;
conditions;
• project location;
• framing connection locations and
required type (eg cast-in) and the • concrete element number;
capacity of the fixing inserts; • the mass of each concrete element;
• levelling pad details; • concrete element dimensions and
• structural design criteria affecting centre of gravity;
construction, eg wind design loads, • structural reinforcement and concrete
tolerances; cover dimensions;
• the concrete specification including all • the size, configuration and concrete
special requirements to meet in-service cover of any additional reinforcement
loadings and conditions and a note that required for the transport and lifting
all concrete must meet the strength of the concrete element;
requirements at the time of lifting
nominated on the panel shop drawings; • the location, orientation and depth of
all inserts and the size, configuration
• base connection details, eg grouting and concrete cover of any component
sequence of dowel connections; and reinforcement that is required. All
• location of services such as plumbing, edge-lift inserts and some other inserts
electrical and cabling conduits. require component reinforcement and
details should be obtained from the
suppliers of these items;
5.2 Panel documentation • location of any conduits for
Concrete panel documentation consists of a plumbing, electrical or cabling;
marking plan, shop drawings and erection • location of grouting ducts and, where
documentation for the concrete elements. required, lateral restraint details;
Panel documentation should be available at
the site whenever work is carried out.
page

36
• the type, make, capacity and 5.2.3 Erection documentation
technical specifications of:
Documentation should be provided and
- lifting inserts; signed by the erection design engineer
which shows:
- bracing inserts and fixings;
• rigging details, including sling
- fixing inserts; and, if required
lengths;
- strongbacks, strong back fixing
• configuration and size of erection
inserts and locations;
braces and, where applicable, knee
• the class and strength grade braces and cross-bracing;
designation of the concrete as
• propping details if required;
defined in AS 3600;
• requirements for erection brace
• the required concrete compressive
footings (and prop footings if
strength of the element, bracing
required), brace fixings and concrete
footings and prop footings (if required)
strength of the footings at time of
as applicable at the time of lifting and
erection; and
erecting. Concrete strength grades
higher than that specified on the • levelling pad details.
structural drawings may be necessary
In situations where the rigging differs
to achieve the concrete strengths
from a configuration shown at Figure
required at the time of lifting;
4.3, the rigger should prepare a rigging
• the surface finish of each concrete diagram detailing the required
element; configuration with sling lengths,
spreader/lifting beam requirements and
• where appropriate, the tolerance
arrangement of sheaves.
limits on the concrete element (see
section 4.5.3 of this code);
• the orientation (position relative to 5.3 Lodgement of shop
each other) of the concrete elements: drawings with local
and
government
• rigging details.
A copy of the approved shop drawings
The shop drawings should be signed should be lodged with the relevant local
and dated by the project design government authority for filing with the
engineer and the erection design relevant building licence.
engineer. A sample shop drawing,
Information contained in the shop drawings
illustrating some detail, is shown at
will assist in the consideration of any future
Appendix B.
modification work and the safety of any
Before being made available on site, future demolition of the building. The
shop drawings should be subject to an Department of Local Government and
approval process whereby they are Regional Development intends to make this
reviewed by the project design engineer, lodgement a requirement of the Building
erection design engineer and building Regulations 1989.
designer. Any necessary amendments
should be marked up and returned to
the shop detailer for incorporation into
the shop drawings. These amended
drawings are the approved shop
drawings which should be available on
site. See section 1.3.2 of this code.
page

37
 Part 6
Casting
C O N T E N T S

PAGE
6.1 General ................................................................... 39
6.2 Preplanning and layout.......................................... 39
6.3 Casting bed ............................................................ 39
6.4 Formwork................................................................ 40
6.5 Tolerances .............................................................. 40
6.6 Reinforcement ......................................................... 41
6.7 Manufacturer’s statement and inspection .............. 41
6.8 Placement and compaction of concrete ................. 41
6.9 Curing and release agents...................................... 41
6.10 Lifting, bracing and fixing inserts .......................... 42
6.11 Element identification............................................. 42
6.12 Stripping and repair ............................................... 42
page

38
Casting
6.1 General • for face-lifted concrete panels,
assessment of the true working radius of
Concrete elements should be manufactured in the crane should be made by adding at
accordance with the approved shop drawings. least 1.5 metres to the final panel
position radius. (See section 8.6 and
Figure 6.1); and
6.2 Preplanning and layout
• usually the crane will be set up such that
Prior to manufacturing the concrete it does not need to slew greater than
elements, the parties involved in the 180 degrees and the lifting radius is
design, manufacture, transport and erection allowed for over that area. The slewing
process should have planned the complete radius of the crane counterweights
construction and erection sequences. should not be overlooked in relation to
The casting and erection sequences of the any braces installed after crane set up.
concrete elements should be agreed between For concrete panels, the casting sequence
the builder and erector. The builder, in should reflect the erection sequence. To
association with the erector, should prepare avoid multiple handling with stack-cast
plans showing the erection sequence and concrete panels, the top panel should be
bracing layout in accordance with the erected first.
requirements of section 8.2 of this code.
For concrete panels cast on site, the floor
slab is commonly used as the casting bed 6.3 Casting bed
and crane standing area. Casting beds need to be capable of
Prior to the casting bed being set out, supporting formwork, panels and other
consideration should be given to the loads, particularly where the casting bed is
following: used as the crane standing area. The
builder should obtain verification from the
• the orientation of the panels on the project design engineer that the casting bed
casting bed; can carry the construction loads.
• vehicular access to and around the site; The surface of the casting bed should be
• location of overhead power lines, utility appropriate for the surface finish of the
trenches and other services; concrete element specified on the shop
drawings.
• panel storage locations, where required;
Any cracks and defects in the casting bed
• crane type, size and lifting position; and
may reflect in the cast panels. Where there
• erection sequence and bracing layout. is insufficient room to cast all panels on the
When assessing crane requirements, note casting bed, panels may be cast one on top
that: of another, in reverse order of erection.
Care is needed with this casting method to
• a crane’s maximum capacity refers to its limit the tolerances of a panel, especially
capacity at minimum radius and often flatness, as the deviation may be
bears little relation to its actual capacity cumulative as successive panels are cast
to lift large concrete panels into one on top of another.
position;
Additional casting beds may be constructed
• the selection of crane size needs to be as required.
made with consideration of the
maximum working radius and load from Panels are usually cast with their external
pick up to final positioning; face down to minimise the need for external
patching after erection.
page

39
This illustration
has been
reproduced with
permission from
SAI Global

Figure 6.1: Crane lifting radius

6.4 Formwork • friction forces are increased by vertical

or near vertical sides on a mould. To
Formwork should be designed and reduce friction, mould sides should be
constructed in accordance with AS 3610 and detailed with adequate draw, or should
the requirements of section 6.5 of this code. be released to allow them to spring
See section 6.7 regarding the written back. To avoid overloading lifting
inspection report required before casting of inserts, the mould can be vibrated while
concrete panels is carried out. gently lifting one end of the concrete
element; and
Tilt-up and precast concrete construction
usually requires multiple use and early • both suction and friction can be reduced
stripping of formwork. These requirements by the use of good quality mould
should be taken into account in the design release compounds.
of the formwork. These matters were discussed in section
Formwork design for concrete elements can 4.3.2 of this code.
have a direct bearing on how concrete
elements are cast and handled and on the 6.5 Tolerances
loads imposed during manufacture. In
particular, the following should be noted: The tolerance on deviation from flatness of
the casting bed should be such that the as-
• suction on flat mould surfaces is cast element meets the requirements of
increased by the presence of water. section 4.5.3 of this code.
Suction pressure can be relieved by lifting
gently at one end or edge of the element; The visual impact of element misalignment
may be reduced by the use of various
page

details such as chamfers and arrises.

40
 6.6 Reinforcement The manufacturer's signed statement should
be available on site at the time of lifting
Reinforcement needs to comply with the the elements listed on the statement. See
requirements of AS 3600 and the approved section 6.11 of this code for element
shop drawings. identification.
Reinforcement should be securely fixed and No lifting should take place until the signed
supported in the correct position to prevent statement covering the particular element is
displacement during concrete placement. available on site.
Where plastic tipped metal bar chairs are
used to support reinforcement in external The statement should contain as a
wall panels, care should be taken to ensure minimum the information contained in the
that the plastic tips are not damaged during form at Appendix B.
or after casting. Records should be kept to substantiate the
manufacturer’s statement.

6.7 Manufacturer’s
statement and inspection 6.8 Placement and
Prior to placing concrete, the form compaction of concrete
arrangement and set up should be Prior to placing concrete, release agent
inspected for compliance with the shop effectiveness should be checked by
drawings. In particular, this should include sprinkling water over the casting bed. If the
checks on: release agent is effective, the water should
• formwork dimensions; form into beads.

• formwork stability; The concrete supplier should be advised of:

• panel edge details and penetrations; • the specified characteristic concrete

compressive strength;
• connection details;
• the concrete compressive strength
• insert locations, types and fixing to required at time of lifting;
reinforcement;
• the required maximum aggregate size;
• reinforcement size, location, concrete
cover and fixing; and • the required slump;

• bond-breaker effectiveness. • special design requirements, if any, eg

cement content, water-cement ratio and
The inspection should be carried out by a colour; and
competent person who was not directly
involved in the original assembly of the • the site access, required rate of supply
formwork, reinforcement and hardware and the method of placement, eg type
components. For stack casting, an of pump.
inspection should be done prior to the Concrete should be placed in a uniform
casting of each panel. manner and evenly spread over the area
For concrete panels cast on or off-site, before commencing compaction. Vibrators
regulation 3.88G requires a written report of should be used to compact the concrete.
this inspection to be kept at the site Particular attention and care needs to be
whenever tilt-up work is being carried out. paid to vibrating the concrete around the
inserts and adjacent to corners and edges.
Prior to the transportation or erection of
concrete elements, the builder should
provide to the erector a statement signed 6.9 Curing and release agents
by the manufacturer stating that the
manufacture of the elements was carried The curing compound and release agent
out in accordance with the engineer should be applied in accordance with the
approved shop drawings. For site casting manufacturer’s specification and the
Regulation 3.88G
this statement should be signed by a requirements of section 3.3 of this code.
competent person.
page

41
 6.10 Lifting, bracing and 6.11 Element identification
fixing inserts All concrete elements should be
Variations should not be made to the permanently marked during or immediately
specified insert locations on the approved after manufacture with a unique
shop drawings without the written approval identification designation, commonly the
of the erection design engineer. If changes concrete element number, and date of
are made, the shop drawings should be casting.
amended accordingly.
All cast-in inserts and any component 6.12 Stripping and repair
reinforcement should be accurately
positioned and securely fastened in Formwork should be carefully stripped and
accordance with the supplier's stored to prevent damage.
recommendations, and as detailed on the If the concrete element suffers damage
shop drawings, to prevent dislodgement greater than minor spalling, the proposed
during concrete placement. repair system should be approved in writing
Inserts should not be welded to by the project design engineer before being
reinforcement. carried out.
page

42
Part 7
Handling, storage
and transport
C O N T E N T S

PAGE
7.1 General 44
7.2 Handling and storage of site-cast
concrete panels 44
7.3 Handling and storage of factory
manufactured concrete elements 44
7.4 Transport 46
7.4.1 General 46
7.4.2 Preplanning 46
7.4.3 Loading 46
7.4.4 Support frames 46
7.4.5 Element protection 47
7.4.6 Delivery 47
page

43
 Handling, storage
and transport
7.1 General The general requirements for handling and
storage of concrete panels on site are as
Methods for handling and storage of follows:
concrete elements will vary depending on
the type of element and whether the • panels should only be stored in a
concrete element is cast on-site or off-site. position approved by the erection design
engineer. Panels should preferably be
Concrete panels cast on site should only be stored in the vertical position;
stored in a designated area and in such a
manner as to minimise multiple handling. • ground conditions need to be checked
by an engineer to ensure that the mass
There is always a risk to safety of persons of the element and any necessary
involved and a risk of damage to a stacking frames can be supported; and
concrete panel every time it is moved.
Careful planning and scheduling will • where a panel is to be stored
minimise the need to relocate panels. A horizontally or on a suspended floor
panel should not be relocated without first slab, approval and written instructions
discussing the need with an engineer. should be obtained from the project
design engineer before proceeding.
Factory manufactured concrete panels and
other concrete elements should be retained Where edge-lifted panels are stored
in the precast yard and delivered to site for horizontally, they should be placed as
installation as required. originally cast to ensure that component
reinforcement around edge lifting inserts is
The rigging system to be used for each correctly oriented for re-lifting.
concrete element must be as set out in the
erection documentation detailed in section Where panels are stored in areas of vehicular
5.2.3 of this code. movement, protection by way of bollards or
other physical barriers and appropriate
Concrete elements should not be lifted warning signs should be considered.
without the appropriate methods being
documented. During handling and storage, care should
be taken to minimise the likelihood of
impact between the concrete panels.
7.2 Handling and storage of
site-cast concrete panels 7.3 Handling and storage of
Where storage of site-cast concrete panels factory manufactured concrete
is required the storage area should be:
elements
• well drained and consolidated;
Recommended practices and procedures for
• located where there is little chance of handling and storage of precast concrete
damage to the panels to be stored; elements can be found in the Precast
Concrete Handbook referenced in Appendix C.
• adequate to support the weight of the
panels and any necessary stacking With proper preplanning and discussion of
frames; and delivery arrangements between the builder
and precaster, handling of factory
• unlikely to settle unevenly.
manufactured concrete elements can be
The storage area needs to provide adequate minimised.
room for lifting equipment and for
Precast concrete elements are usually
manoeuvring trucks (if required) and cranes.
stored horizontally, however wall cladding
Racking systems, frames and supports for panels are usually stored vertically by using
panels should be constructed in accordance A frames or a racking system.
page

with a design prepared by an engineer.

44
 For horizontally stored concrete elements, • support points should be directly above
only two points of support should be used each other, not misaligned;
if possible, located to minimise stresses on
• stacked elements should be of equal
the element. If more than two supports are
length;
necessary, care should be taken to ensure
the concrete element does not bridge over • softwood supports should be used to
one of the supports. reduce edge chipping and minimise
staining. Hardwood supports may cause
General guidelines for handling and storing
staining of concrete which may be
precast concrete elements are as follows:
difficult to remove; and
• wherever possible, elements should be
• storage should be planned to minimise
stacked at only two support positions,
handling before delivery.
one fifth of the length of the element
from each end for wall units; See Figure 7.1 for correct horizontal
stacking of concrete panels.

This illustration has

been reproduced from
the “Precast Concrete
Handbook” with
permission from the
National Precast
Concrete Association
Australia.
Units should be stacked with suitable
packings, near ends for beam and slab
units and at L/5 from ends for wall units

DO NOT use misaligned packers DO NOT use more than

two support points

DO NOT place shorter units DO NOT place longer units

on longer ones on shorter ones

Figure 7.1: Horizontal stacking of factory manufactured concrete panels

page

45
 7.4 Transport The precaster should advise the
transporter of any special requirements
7.4.1 General for support and restraint of the concrete
elements.
To reduce hazards, the transport of
concrete panels should be avoided Special restraints may be required for
wherever possible. Preplanning will long concrete elements, especially when
reduce the need to transport concrete transporting over long distances.
panels around the site. The equipment should be inspected
before use to ensure it is serviceable.
7.4.2 Preplanning
Concrete elements should be loaded so
The following points should be taken that identification marks are visible prior
into account when transporting concrete to and during unloading.
elements and whenever it is necessary
for concrete panels to be transported to The location of lifting inserts on the
or around the site: concrete elements should be checked to
ensure they are compatible with the
• the shape, size and mass of the lifting system used. Lifting inserts should
concrete elements; be clearly identified to assist in the
• specific design requirements, loading and unloading stages.
including the concrete strength The transporter needs to ensure that
required for transportation and the drivers have been adequately instructed
stability of long or unusually shaped in the safe transportation of the
panels during transportation. The concrete elements, with particular
precaster needs to ensure the attention given to:
concrete element has reached the
design concrete strength prior to • power lines;
transportation; • recognised truck routes for over-
• traffic regulations governing dimensional loads; and
maximum weight, length, width and • roundabouts and reverse camber in
height of the laden vehicle; the roads.
• all-weather access for the delivery Differential road cambers may induce
vehicle and the traffic management torsional loads in long panels. Slender
plan referred to in section7.4.6 of concrete panels may require temporary
this code; stiffening against lateral buckling.
• capacity of any permanent structures The transporter should be responsible for
to carry transport loads; and obtaining the permit for all over
• temporary storage, where required. dimensional loads. Drivers should be
able to produce the permit upon request.
7.4.3 Loading Drivers should stop and check the load
The concrete elements should be loaded and the restraints shortly after
in a sequence compatible with the commencing the journey. Restraints tend
required unloading sequence on site. to loosen due to settling of the load
and stretch of the restraints, particularly
Secure restraint of loads on vehicles is
if webbing straps are used.
important in preventing accidents and
injuries. Load restraints may be chains 7.4.4 Support frames
or webbing straps.
Frames used to support concrete
The adequacy of a particular method of elements during transport need to be
restraint will depend on the type of designed to withstand loads and forces
concrete element being transported and acting on the system during loading,
the type of vehicle being used. transportation and unloading.
page

46
A frame system that is not an integral The builder should provide a documented
part of the transport vehicle or trailer traffic control management plan that
should be adequately secured and includes, where necessary, traffic
capable of withstanding any forces controller, barricades and road closure
applied during loading, transportation permits to allow unimpeded access to the
and unloading. site. This traffic management plan should
form part of the work plan which must be
Particular care needs to be taken during
available on site at all times when work
loading and unloading concrete elements
is carried out.
from frames to ensure the frames remain
stable at all stages. The precaster needs to ensure that the
transporter has detailed instructions on
7.4.5 Element protection how to enter the site.
Points of contact between concrete The transporter should inspect the site
elements, supports, and restraints prior to entry to verify there are no
should be provided with protective dangers such as uncompacted backfilled
material to prevent breakage and excavations or overhead services. The
staining. Corner protectors should be area to receive the delivery vehicle
used under all restraints to prevent should be firm and, where possible, level.
movement and damage to the concrete
The transporter should position the
element.
vehicle as directed by the erector and
Low friction material should not be used stabilise the vehicle prior to releasing
as packing between concrete elements the concrete element restraints. Where
and supports. possible, semi-trailers should be
Where concrete elements are transported stabilised by lowering the support legs
horizontally, they should be stacked so onto a firm base. The transporter needs
that each element can support the loads to be aware of which elements are to be
from above. The support points should unloaded first.
be directly above each other unless The builder needs to ensure that the area
specifically designed otherwise. where the crane is to be set up is stable,
The stacked height of concrete elements compacted if on the ground, and able to
should be limited to ensure that the support the crane when loaded and
bearers and lowest elements can positioning concrete elements in their
support the loads from above and that storage or erection positions. The crane
the stack remains stable during operator should check these factors with
transportation. the builder prior to handling any concrete
elements. See section 8.5 of this code.
Particular attention needs to be given to
prestressed concrete elements to ensure If the unloading sequence can lead to
they are only supported at designated instability of loads, the concrete
bearing points and that restraint systems elements should be individually secured.
do not impose excessive loads. Individual elements should not be
Prestressed concrete elements should released until the crane has taken the
not be supported, even temporarily, at initial load of that element.
any other points and they should not be
tipped sideways.

7.4.6 Delivery
Delivery of concrete elements onto the
site requires co-operation between the
builder, precaster, transporter and
erector.
page

47
 Part 8
Erection to temporary
braced condition
C O N T E N T S

PAGE
8.1 General ......................................................................... 49
8.2 Planning the construction and erection sequence ...... 49
8.3 Work method statement .............................................. 50
8.4 Exclusion zones............................................................ 51
8.5 Crane standing area ..................................................... 51
8.6 Planning cranage requirements ................................... 51
8.7 Operating near overhead power lines ......................... 53
8.8 Operating near braces and panels .............................. 55
8.9 Working at height ........................................................ 56
8.10 Strongbacks.................................................................. 57
8.11 Erection crew................................................................ 57
8.12 Rigging.......................................................................... 57
8.13 Erection of concrete panels ......................................... 58
8.14 Modifications ................................................................ 59
page

48
Erection to temporary
braced condition
8.1 General • underground power lines and other
services; and
Safe erection of concrete panels and precast
concrete elements depends on the • underground tanks and soakwells.
preplanning process. All personnel should be A crane layout drawing should be prepared
aware that erection of these elements is showing the working radius of the crane.
potentially hazardous and the purpose of the
The planning process should ensure the
pre-planning process is to identify hazards
on-site provision of:
and control any risk in the erection process.
• supervision;
The actual lifting of concrete panels is the
time when potential for serious accident is • induction training;
highest.
• adequate first aid facilities, workplace
Due to their large surface area and mass a amenities and personal protective
great deal of care needs to be taken when clothing and equipment in accordance
lifting, moving and securing concrete panels with the Commission for Occupational
into position. The likelihood of fatalities if a Safety and Health code of practice on
panel falls over is considerable. Increasing the provision of these services and
the risk is the fact that the crane may fall equipment as appropriate;
over and other panels that are struck by
• perimeter fencing around the site to
the crane or falling panel are also likely to
prevent access by members of the
collapse. With these factors in mind it is
public. Link mesh fencing 1.8 metres
extremely important that both the panel
high will generally be required to
erection crew and crane operator are highly
provide sufficient public protection.
skilled and experienced in the erection of
Other forms of protection may be
concrete panels.
suitable in some situations;
Requirements for training and supervision
• adequate access for the type of
are set out in section 2.2 of this code.
construction methods to be employed;
• adequate access for the size of the
8.2 Planning the construction crane to be used;
and erection sequence • adequate access for semi-trailers and
Prior to erecting concrete elements, the transport equipment;
builder, in association with the erector, • height access equipment appropriate to
should have planned the complete the construction methods;
construction and erection sequences.
• access to approved shop drawings; and
The planning process should take into
• risk assessment giving particular
account:
attention to overhead power lines at or
• site limitations and local street access; adjacent to the site.
• concrete element sizes; The rigging system needs to be designed to
• crane size configuration, mobility and suit the spacing and layout of the lifting
access; inserts. See Figure 4.3 for preferred rigging
configurations.
• compaction of site surface areas;
Sling lengths are critical where the rigging
• casting sequence; system includes the use of spreader beams
• overhead obstructions, particularly or lifting beams with slings running through
overhead power lines and construction sheaves.
page

site overhead power;

49
 Before erection commences, the builder and panels and ensure that nominated braces
erector should: are fitted to the panels;
• confirm that the erector's risk assessment • in consultation with the rigger:
is appropriate and has dealt with all
- determine if load distribution on lifting
aspects of the erection procedure,
points is satisfactory;
including appropriate exclusion zones;
(see section 8.4 of this code) - ensure that the appropriate rigging
equipment is available and is
• make sure that crane and truck access is
serviceable;
inspected and confirmed as safe;
- ensure that braces do not interfere
• inspect the crane standing area and
with the rigging;
confirm that it is safe. Obtain verification
from an engineer that the crane standing - check that lifting inserts are compatible
area can safely support the erection with lifting clutches and are in their
loads; (see section 8.5 of this code) correct location and that recesses are
cleaned out in preparation for lifting;
• make sure the crane operating area has
been cleared to provide adequate room - determine an appropriate interval for
for crane outriggers, counterweight tail checking the condition of braces, and
swing, boom swing and under-hook and torque on brace bolts, to ensure they
overhead obstructions, including have not become loose; and
overhead power lines. Refer to section • determine if weather conditions are
8.6 of this code for points to be adequate for erection.
considered in planning cranage
requirements;
• ensure that provision has been made for 8.3 Work method statement
safe working at heights, if necessary; A work method statement should be
(see section 8.9 of this code) prepared, usually by the erector, in
• confirm the erection crew members are consultation with the builder and the Safety
properly certificated and trained and and Health Representative (if any) of the
available in adequate number; (see workers. In the absence of a Safety and
section 8.11 of this code) Health Representative, the work method
statement should be prepared in consultation
• verify that the element concrete (and
with the erection crew and reviewed by the
brace footing concrete) has attained the
Safety and Health Representative (if any)
specified strength for lifting and
following their election.
nominated brace fixing bolts are
available on site. If the element concrete The work method statement needs to be
does not achieve the specified strength specific to the project and based on the
for lifting in accordance with the documentation detailed in Part 5 of this
requirements of section 3.2 of this code, code. It should be signed off by the builder
the erection design engineer should be and erector. The work method statement
notified before lifting occurs; should provide a general description of the
erection process, identifying the objectives
• check that strongbacks, if required, are
of the erection process and broadly
available and are correctly installed;
describing how these objectives are to be
• make sure that locating dowels or other realised. Most importantly it should set out
horizontal restraints are fitted prior to the safe working procedures to be used
lowering concrete elements and levelling during the erection process.
shims are correctly located;
Sample documents for erection of concrete
• confirm that the means of support, elements are provided at Appendix B.
including falsework, is adequate for the Sample documents for casting of concrete
intended purpose and is correctly located; elements and incorporation of structural
steel into the final structure are also
• check that sufficient clear space is
provided at Appendix B. These documents
available for the safe propping of precast
include schedules for the concrete elements.
concrete elements or bracing of concrete
page

50
 8.4 Exclusion zones the public and traffic should be prevented,
as far as practicable, from passing through
Regulation 4.53 Regulation 4.53 requires, as far as the zone while concrete elements or other
practicable, that loads are not suspended items are being lifted and prior to securing
over, or travel over, a person. concrete panels with braces.
Only persons directly involved with the
lifting of concrete elements should be
located in an area where the lifting is 8.5 Crane standing area
taking place. Such persons should avoid Before erection commences, the builder
being in a position where they could be should supply the erector with written
struck in the event of a concrete element verification from an engineer that the crane
falling or a crane or panel falling over. standing area (floor slab, suspended slab or
The Act, section Under section 21(1)(b) of the Act, employers surrounding ground, etc.) can safely carry
21(1)(b) the construction and erection loads.
and self-employed persons must, as far as is
practicable, ensure that the safety and The project design engineer should provide
health of non-employees, including members this verification where the crane standing
of the public, is not adversely affected by area forms part of the structure.
their work or the work of their employees.
If the crane is to be set up on the ground,
The Act, section In addition, persons having control of a
22(1)
compaction tests should be taken of the
workplace have a responsibility under the area to ensure the loads imposed by the
Act (section 22(1)) to take all practicable crane can be supported.
measures to ensure that people who are
not employees who are at the workplace, or Backfilled excavations, trenches and
likely to be at the workplace in the course soakwells should be identified and
of their work, or enter or leave the assessed. Additional measures, such as the
workplace, are not exposed to hazards. provision of timber mats, may need to be
taken to ensure that any backfilling can
To satisfy these legislative responsibilities support the construction and erection loads.
exclusion zones should be set up to
prevent, as far as practicable, unauthorised
persons gaining access to areas where 8.6 Planning cranage
lifting of concrete elements or other items
requirements
is taking place.
Cranage planning should commence as
This may necessitate the erection of para-
early as possible in development of the
webbing, signage and/or fencing depending
project.
on the ease of access and the likely
presence of workers or members of the The requirements for cranes should be in
public. All members of the public and accordance with section 3.8 of this code.
workers not involved in the lifting of It is essential to ensure all lifts can be
concrete elements or other items should be carried out while keeping a safe distance
prevented, as far as practicable, from from power lines and obstructions, never
accessing an exclusion zone while lifting is operating over any person, road traffic,
taking place. The provision of perimeter unprotected public space, unprotected site
fencing around the site will assist the offices or amenities sheds.
operation of exclusion zones.
In accordance with the requirements of Regulation 4.54
Where a common boundary between two regulation 4.54, cranes and elevating work
properties is located in an exclusion zone, platforms (EWP) must be maintained,
an effective means of communication with inspected and operated in accordance with
occupiers is essential to keep members of the written instructions of the designer or
the public away from the exclusion zone manufacturer of the crane. If it is not
while lifting is taking place. This issue practicable to obtain these instructions the
should be addressed in the planning stage WorkSafe Western Australia Commissioner
(see section 8.2 of this code). may approve written instructions. If it is not
Where a footpath, road or other access way practicble for the person in charge of the
is located in an exclusion zone, members of workplace to get either of these forms of
page

51
 instruction then the requirements of AS • emergency procedures; and
2550.1 and AS 1418.1 should be followed,
• protection of the public.
together with the requirements of any other
part of AS/NZS 2550 and AS/NZS 1418 that The maximum rated capacity or WLL of a
are relevant. crane refers to its maximum load capacity
at the minimum radius. This must not be
The selection of an appropriate mobile
confused with its actual capacity at working
crane, preparation of the site and correct
radius when lifting.
location of the crane are crucial in ensuring
the safe erection of concrete elements. As a general “rule of thumb”, cranes used
Mobile cranes used for this type of on tilt-up work should have a maximum
construction are often required to work capacity of at least three times the weight
close to their maximum capacity with high of the heaviest concrete panel to be lifted.
luff angles due to the large size and mass In some situations a smaller crane will be
of concrete panels. These factors increase acceptable and in some situations a larger
the likelihood of the crane overturning, crane may be required where large
particularly if the ground is not level. All irregularly shaped elements are to be lifted
Regulation 3.23 cranes used for the lifting and erection of or where the crane cannot be positioned
concrete elements should be fitted with load close to the casting bed or final position of
indicators as described in regulation 3.23. the panels.

The crane should be located with Larger cranes are generally more difficult to
consideration given to the erection manoeuvre around the site. However site
sequence of the concrete elements to avoid movements may be minimised with large
any possibility of the rear of the crane cranes. Of utmost importance is the need to
slewing into braces supporting previously ensure the crane does not damage the
erected concrete panels. structure or braces when operating,
especially slewing.
Where two or more cranes are operating
they should be sited so as to prevent them The extra cost of a large crane may be
operating in each other’s airspace. justified by a shorter overall erection time.

At appropriate stages, the planning process For all face-lifted concrete panels, the true
needs to consider: working radius of the crane needs to include
an allowance of at least 1.5 metres over the
• crane selection, access and siting in
radius to the panel's final position to take
accordance with AS 2550;
account of the hang of the panel from the
• ground support conditions and the lifting inserts and any lifting beams, etc.
location of any excavations or (see Figure 6.1). This may need to be
underground services likely to be increased for tall panels. An assessment of
adversely affected by imposed crane loads; the true working radius should be made
• proximity of overhead power lines; according to individual panel details.

• written procedures for setting up and Where lifting is not possible with one crane
dismantling the crane and the lifting and it is necessary to use two cranes to
method as well as a risk assessment of "dual lift" concrete elements, the required
these procedures; crane capacities should be carefully assessed.
In accordance with regulation 4.54 the rated
• the make-up of the crane crew
capacity of each crane must exceed the Regulation 4.54
appropriate to the particular
crane’s share of the load by at least 20%.
circumstances of the job;
• the communication system; Dual lifting is a potentially dangerous
operation requiring a great deal of skill by
• selection of lifting gear including operators. Regulation 4.54 requires that
appropriate snatch block for rotation of dual lifting only be carried out where the
panels while suspended if rotation is to physical dimensions and mass of the load
be carried out (see section 3.8 of this prevent the load from being handled by a
code); single crane that is readily available. The
• personal protective equipment for the regulation also requires direct supervision
rigging crew;
page

52
 This illustration
has been
reproduced with
permission from
SAI Global

Figure 8.1: Clearance for cranes from overhead power lines

by a competent person not otherwise Builders should plan ahead as far as

involved in the operation. possible to maximise safety. Electricity
distribution authorities can isolate most
Dual lifting should never be carried out
overhead power lines when sufficient notice
where wind speeds exceed those specified
is given and every attempt should be made
by the crane manufacturer.
to achieve isolation.
“Blind” lifting, where the rigging is on the
Where overhead power lines are isolated,
side of the concrete panel opposite to the
the electricity distribution authority’s access
crane, should be avoided because the crane
permit should be kept in the crane
operator and rigger will be unable to
operator's possession during operations.
visually check the rigging during lifting. Very
importantly, if failure should occur, the Where there is no access permit, all power
panel will fall towards the crane. “Blind” lines must be treated as being live and
lifting may be unavoidable in some without written confirmation of the line
situations such as when placing a closure voltage from the supply authority, the
panel in a building. highest line voltage must be assumed and
a 6 metre “danger zone” used.
Regulation 3.64 of the Occupational Safety Regulation 3.64
8.7 Operating near overhead and Health Regulations specifies a “danger
power lines zone” around overhead power lines of
Wherever plant is required to work near different voltages, which must not be
overhead power lines a severe hazard is entered by employees, plant or material.
created. This occurs in many types of This “danger zone” is within:
construction activity.
(a) 0.5 metres for insulated overhead line
In the case of precast and tilt-up or aerial bundled conductor line not
construction, cranes often operate in close more than 1000 volts;
proximity to overhead power lines and the
risk of injury can be very high. (b) 1.0 metre for uninsulated overhead line
not more than 1000 volts;
page

53
 (c) 3.0 metres for overhead line exceeding • install warning notices in a prominent
1000 volts but not more than 33000 position in the crane cabin to alert
volts; and operators to check for the presence of
power lines;
(d) 6.0 metres for overhead line exceeding
33000 volts. • dry taglines (tail ropes) made of non-
conductive material such as natural fibre,
WorkSafe Western Australia’s Guidelines for
hemp or sisal should be used to control
Work in the Vicinity of Overhead Power
the load. Due to their conductive
Lines provides guidance on the operation of
properties, synthetic ropes should not be
cranes and the use of other plant and
used. The tagline should be prevented
equipment in the vicinity of overhead power
from approaching or being blown into
lines. The Guidelines promote a “no go”
contact with any power line; and
distance beyond the “danger zone” which
should not be entered by the crane lifting • mobile cranes should be provided with a
hook. This “no go” distance is the steel earthing chain. The chain should
horizontal distance from the centreline of be bolted or welded to the carrier
the crane hook to the perimeter of the load chassis and be of sufficient length to
which for concrete panels is half the length allow at least one metre of chain to be
of the lifted edge. in contact with the ground when the
crane is set up on outriggers. Earthing
The “no go” distance may need to be
chain should not be used when the
increased if panels are laid down away from
crane is operating near the rails of an
the crane, particularly for high panels where
electric train system.
the risk of making contact with overhead
power lines is increased. When operating or travelling in an
unfamiliar area, the crane operator should
Figure 8.1 shows required clearances for
always check for the presence of overhead
cranes from overhead power lines in
power lines.
accordance with WorkSafe Western
Australia’s Guidelines. In the event that the crane does contact
live power lines, or arcing occurs, the crane
If, for any reason, it is necessary for a
operator should observe the following
person or any plant, material or equipment
precautions:
to enter the “danger zone”, the prior
authorisation of the supply authority must • remain inside the cabin;
be obtained before entry is made.
• warn all other personnel to keep away
In instances where it is necessary to operate from the crane and not to touch any
the crane within the “no go” zone (but still part of the crane, rigging, tail ropes or
outside the “danger zone”), a dedicated load;
spotter should be used throughout these
• try, unaided, and without anyone
phases of the erection sequence. In these
approaching the machine, to move the
circumstances, the erector should also
crane until clear of the power line;
implement the following measures:
• if the machine cannot be moved away,
• increase the visibility of the power lines
remain inside the cab. If possible, by
by arranging with the supply authority
using a safe means of communication,
the installation of “tiger tail” wrapping
get someone to inform the electricity
around the lines;
distribution authority at once. Take no
• slow down the normal operating cycle of action until the distribution authority
the crane to increase the available confirms that the conditions are safe;
reaction time for assessing distances;
• if it is essential to leave the cabin
• keep persons not authorised by the because electrical contact or arcing has
erector away from the area; caused a fire or other life-threatening
emergency, jump clear as far away from
• clearly instruct all personnel to stand
the crane as possible. Do not touch the
clear of the crane and load at all times;
crane and the ground at the same time;
page

54
 This illustration
has been
reproduced with
permission from
SAI Global

High voltage contact

will result in electrical
current flowing down the boom
and through the crane to the ground.
The ground will then be energized with a high
voltage near the crane and lower voltage further away.

Figure 8.2: High voltage contact

• when moving away from the crane, possible degradation of rubber tyres caused
shuffle or hop slowly across the affected by high temperatures.
area. Large steps should be avoided as
All tyres suspected of being subjected to
one foot could be in a higher voltage
heat from any source should be replaced.
area and the other in a lower voltage
area. Under some circumstances, the Proximity warning devices, insulating boom
voltage difference between the two guards and similar devices all have
areas could kill (see Figure 8.2); and limitations and should not be relied upon
to give protection against electric shock.
• ensure someone remains near the crane,
at a safe distance, to warn others of the
danger of approaching.
8.8 Operating near braces
Following any contact with live power lines and panels
or arcing, a competent person should
inspect the crane for possible damage The use of mobile plant such as cranes,
caused by the contact before further use. backhoes, excavators and EWPs, close to
Wire rope should be replaced if it touches concrete panel braces can be extremely
the power line as the arc will usually weld, hazardous due to the risk of panels and
melt or badly pit the rope. braces being struck and panels collapsing.
Braces are designed to resist wind loads
In the case of wheeled machinery it is applied to panels and not to resist impact
important that this inspection consider the loadings with moving plant.
page

55
 Braces that are struck by mobile plant may 8.9 Working at height
collapse in a very rapid and uncontrolled
All work at height should be carried out in Regulations
fashion causing panels to fall. A falling 3.48 to 3.57
panel is likely to strike other panels and accordance with regulations 3.48 to 3.57
progressive collapse of other panels can and the Commission for Occupational Safety
occur. and Health Code of Practice Prevention of
Falls at Workplaces.
The hazard can be minimised by giving
careful consideration to siting of the crane The above regulations and code of practice
and the erection sequence as discussed at contain requirements and advice on edge
section 8.2 of this code. protection, fall prevention systems,
scaffolding and ladders for safe working at
The builder should be notified of any heights.
instance where braces are struck by plant.
Useful information may also be found in
Particular care needs to be taken when a AS 3828.
crane is being used to erect structural
Regulation 3.55 specifies that where there Regulation 3.55
steelwork to prevent parts of the crane and
the suspended load from hitting braces and is a risk that persons could fall 2 metres or
panels. Erection of steelwork in accordance more from the edge of a scaffold, fixed
with the requirements of AS 3828 will stair, landing, suspended slab, formwork or
minimise the risk of contact occurring. falsework, guard railing comprising a top
rail, mid rail and toeboard, or top rail,
Mobile plant should not be operated, or toeboard and meshing must be provided.
travel close to, erected concrete panels and
braces unless there is sound reason, eg the Regulation 3.55 also requires that where
use of an EWP to assist in the installation there is a risk that persons could fall 3
or removal of braces. metres or more from any other edge, edge
protection in the form of guard railing
Where it is necessary to operate plant in mentioned above, or alternatively a fall
close proximity to braces and panels, injury prevention system, must be provided.
control measures should be implemented.
Control measures include the following: To reduce the need for working at height, as
many sections of the structure as possible
• use of a spotter to signal the plant should be assembled on the ground before
operator to stop the plant in the event being lifted into their final position. However,
of any part of the plant approaching a personnel are generally required to work at
brace or panel. Such a system would height to perform the following activities:
need to ensure the communication
method between the spotter and • removal of braces from concrete panels;
operator was effective and take into • attaching the panels to one another or
account factors such as noise on site to structural steelwork prior to removal
and the spotter possibly being out of of the braces; and
view of the operator;
• application of caulking to vertical joints
• use of barricading to ensure separation between panels.
of plant and braces; and
Work at height should either be performed Regulation 3.26
• use of hazard tape, ‘para-webbing’ from platforms with guardrails, including
and/or signage to make the brace EWP, or mobile scaffolding. Portable
position obvious, particularly where ladders should only be used where other
braces are close to access areas. methods are impracticable. Their use must
Any excavation work carried out in the comply with regulation 3.26.
vicinity of brace footings should be Boom lift type EWP are usually preferable
approved by an engineer to ensure footings to scissor lifts because they have superior
are not undermined. reach to access more awkward areas and
do not need to be driven next to an
erected concrete panel to gain access. Also
‘rough terrain’ type boom lifts are more
suitable for poor ground conditions.
page

56
Regulation 4.54 The use of EWP on site must be in The crane operator must hold a certificate Regulation 6.3
accordance with regulation 4.54. The of competency appropriate for the type and
requirements for maintenance, inspection capacity of crane in use.
and operation were mentioned in section Regulation 4.54
The size and make-up of the remainder of
8.6 of this code.
the erection crew is specified in regulation
Before specifying or using an EWP, a check 4.54 and is dependent on the maximum
should be made as to its suitability for the rated capacity of the crane used.
site conditions.
All members of the erection crew should
have been trained in this code of practice,
and at least one of the erection crew or
8.10 Strongbacks another person who remains on site
Strongbacks should be located and fixed in throughout the erection should hold a
accordance with details shown on the shop current first aid qualification.
drawings.
Strongbacks should be bolted so they are
hard up against the panel, otherwise they
8.12 Rigging
may not adequately prevent damage to the Setting up a rigging system requires careful
panel. and thorough preplanning. The selection of
the rigging system connecting the concrete
element to the crane should be agreed
8.11 Erection crew between the erector and the rigger.
The erector should nominate one person in The preferred configurations for concrete
the erection crew to be directly responsible panel lifting are described in section 4.7.3
for the direction and coordination of the of this code and shown in Figure 4.3. Refer
erection sequence. This person should hold to section 5.2.3 for documentation required
a rigging certificate of competency in either for rigging.
the Intermediate Rigging or Advanced
The rigging system should distribute equal
Rigging certificate class and have
loads to all lifting points.
experience in erecting concrete panels.

This illustration
has been
reproduced with
permission from
SAI Global

Figure 8.3: Snatch block

page

57
 Single, double and four leg slings are Concrete panels should not be lifted or
commonly used in the handling of concrete erected before attaining the minimum
elements. In selecting the sling capacity, the concrete strength on the shop drawings for
increased force due to inclination of the lifting or erection.
sling and the change of direction at reeving
If incorrectly located, faulty or missing
points should be considered. The included
lifting inserts are identified, or if concrete is
angle between slings at reeving points
poorly compacted or cracked close to lifting
should not exceed 120 degrees.
inserts, immediate contact should be made
Lifts desirably should be planned so that with the erection design engineer to
rotation of the snatch-block under load is establish an appropriate solution.
not required. Where the snatch block is
It is essential that the order in which the
required to rotate it needs to have thrust
various components and members of the
races or separate swivel bearings as
structure are assembled will maintain
mentioned in section 3.8 of this code.
stability at all stages, allowing for the
An inspection and check of the rigging effects of high winds on partially completed
should be performed prior to lifting by the structures. Overnight it may be necessary to
rigger in charge, especially where steel wire stabilise incomplete structures using
rope is being used in the rigging system. measures considered as part of the initial
This inspection should include a visual check design and forming part of the designed
to ensure the snatch block collar pin is intact erection sequence. They should not be an
and the collar has not become loose. ad hoc means of stabilisation.
Where blocks with lockable clamp bolts are The builder should provide the erector with
not available, care needs to be taken to verification that the concrete in brace
ensure that the cheek plate clamp bolt is footings has attained its required strength
fully tightened and that rubbing and before concrete panels are erected.
abrasion under load does not occur. See
For site-cast panels, the adhesion of the
Figure 8.3.
panel to the casting bed has to be broken.
The rigging system should be arranged to At all times panels should be lifted
allow the concrete element to lie in or near smoothly to avoid shock loading which can
its correct attitude for erection into the induce cracking in the panel.
structure.
For face-lifted panels, load on the crane
All components of the rigging system should should not be increased if the panel does
be checked regularly for damage and not come free when the crane's load
excessive wear, corrosion, etc to ensure they indicator registers the combined weight of
are appropriate for the loads being lifted. the panel, rigging and any attachments
such as strongbacks.
Lifting clutches should be inspected, prior
to each use, for wear and deformation. If For edge-lifted panels, load on the crane
any deterioration is seen or safety concerns should not be increased if the panel does
identified, a proof test should be conducted not come free when the crane's load
as mentioned in section 3.5.2 of this code. indicator registers 65% of the weight of the
panel plus 100% of the weight of the rigging
and any attachments such as strongbacks.
8.13 Erection of concrete In all circumstances where a lift has been
panels stopped, procedures such as wedging or
Concrete panels should be erected in jacking should be as determined by the
accordance with AS 3850 and the work builder. Such procedures need to be
method statement referred to in section 8.3 undertaken or directly supervised by the
of this code. Before erection commences rigger in charge of the erection. Where
the checklist at section 8.2 should be used, wedges should be aligned with the
carried out. line of lifting inserts unless written
instructions state otherwise.
page

58
Each concrete panel should be lifted so that, • all personnel should be clear of the area
while suspended, it leans away from the where the panel may fall when lifting,
crane. The situation when the panel tilts tilting or rotating the panel from
towards the crane is extremely dangerous. If horizontal to vertical;
part of the lifting system fails, in this
• when taglines are used to control the
situation, the panel will fall against the
swing of the panel, personnel should
crane and may cause the crane to overturn.
position themselves clear of the panel
The requirement to lift panels in this manner
edges as the panel may slew sideways.
can exist when panels are cast on the
Clutch release ropes should never be
outside of the building to be constructed.
used as taglines;
Bracing inserts are usually located on the
• no attempt should be made to lift and
same face of the panel as the lifting inserts.
erect panels in strong winds where wind
Good practice dictates that whenever speeds exceed those specified by the
possible, the braces should be fixed to the crane manufacturer;
concrete panel before lifting.
• crane support should be maintained
During the lifting process, the braces should until all braces have been installed and
not hang below the level of the base of the secured to the panel and footings;
panel. This may be achieved by the use of
• the crane operator should never leave the
adjustable length braces or by the use of
crane while the panel is connected; and
taglines.
• no brace should be connected to
Where, under unusual circumstances, it is
another panel for support unless clearly
necessary to attach braces to the panel
specified on the shop drawings.
after it has been positioned, the panel
should be held firmly, just past vertical by After erection of a panel it is the builder’s
the crane while the braces are attached. responsibility to check braces, brace bolts
Where bracing inserts are located on the and pins at regular intervals to ensure they
opposite side of the panel to the lifting maintain the required capacity. These
inserts, the panel should be tilted slightly intervals should be determined by the
back on to the rigging and the braces builder and erector at the preplanning stage
attached. (see section 8.2 of this code). See also
section 9.1, Installation and inspection of
No person should ever work on a concrete
temporary bracing.
panel that is leaning towards them or be
placed between a panel being lifted and
another panel, wall or object, where
8.14 Modifications
movement of the panel could cause
crushing. This applies until the release of Modifications to concrete panels and other
the crane from the panel. precast concrete elements and their
associated supporting components and
The following practices should be followed
connections, may only be carried out with
during the lifting and placing of concrete
the approval of the project design engineer.
panels:
The need for modification may be due to
• lifting gear and sheaves to be in good relocation or changes to sizes of windows
condition and lifting clutches fully and doorways.
engaged prior to lift occurring;
It is a requirement of the Building
• lifting clutch release lines are fitted to Regulations 1989 that the relevant local
enable clutches to be disengaged government authority be notified to obtain
without the need for workers to climb the consent of the building surveyor prior
on top of the panel; to proceeding with any variation from, or
alteration of, approved plans, drawings and
• whenever possible, panels should be
specifications. This requirement, of course,
lifted with the rigging equipment in view
applies throughout the life of the building.
of the crane operator as the crane hook
is hoisted;
page

59
 Part9
Temporary braced
condition
C O N T E N T S

PAGE
9.1 Installation and inspection of
temporary bracing................................................... 61
9.2 Superimposed loads............................................... 62
9.3 Levelling pads and shims ...................................... 63
9.4 Grouting of the base .............................................. 63
page

60
Temporary braced
condition
9.1 Installation and However, where more than two braces are
used there is difficulty in ensuring an even
inspection of temporary load distribution. Allowance should be
bracing made in the design for the potentially
Bracing should be installed in accordance uneven loading where more than two
with AS 3850 and the approved shop braces are used on a panel.
drawings unless prior written approval is Two braces may not be necessary where
obtained from the erection design engineer. concrete panels are provided with erection
The capacity of a brace varies with the brackets or permanent connections to other
installation angle of the brace. restrained elements such as steel portal
Where a single brace is used eg on narrow columns or walls forming a stable “box”
panels, to brace a panel, particular care is structure.
required on site to prevent impact or A brace connected to one concrete panel
damage to the brace. Panels supported by should not be connected to another braced
a single brace only are very susceptible to panel for support unless this is clearly
failure by panel rotation about the brace. specified on the shop drawings.
Where single braces are used, they should The angle of installation of braces should
have a minimum of two fixings at each end. be shown on the shop drawings. Braces are
Care needs to be taken in the installation usually installed at an angle of 450 to 60o
of these two fixings as their closeness may and square to the line of the panel (see
reduce the effective anchorage of each. Figure 9.1) unless the erection design
Usually two braces are used to support engineer has considered another
each panel. Three braces may be necessary arrangement and it is shown on the shop
on large panels and in situations where drawings. If site conditions prevent the
load controlled expansion anchors are used braces from being installed in the positions
in brace footings since the capacity of these shown on the shop drawings, the erection
anchors may be less than the capacity of design engineer should be consulted and
the brace itself. approve an alternate location and any
associated changes necessary such as larger
braces and higher capacity base fixing.

Minimum 20mm
diameter threaded
cast-in insert
Panel
90˚ 90˚
Required capacity of
brace and installation
Panel height

angle to be nominated
Brace Brace
Typically 2/3 panel height

on shop drawings

Type of fixing to be Plan View

nominated on shop
drawings

Floor slab
45-60˚

Figure 9.1: Concrete panel bracing, preferred arrangement

page

61
 Figure 9.2 shows the proper method of 9.2 Superimposed loads
bracing corner panels without having to
skew the braces for attachment to the floor Superimposed loads should not be applied
slab. Attachment of braces to concrete to concrete panels in the temporary braced
blocks (deadman) in the “leave-out area” condition unless clearance is obtained from
between the floor slab and the panels an engineer. Such loads should have been
allows the braces to be properly located specifically allowed for in the design. These
without skew. Panel stability is reduced include loads from erection of steelwork
when braces are skewed. and other attachments.

Bracing feet (or shoes) need to be designed The erection of roof steelwork can exert
to prevent lateral displacement of the shoe significant outward loads onto braced
from the fixing insert after installation. panels. In some cases these forces may be
sufficient to overload the temporary bracing
The preferred location of bracing points in a and cause failure of the bracing
concrete panel is at two-thirds of the inserts/bolts.
height, measured from the base of the
panel and at least 600mm above the centre During release of a rafter’s weight from the
of gravity. Where it is necessary to locate crane, the braces adjacent to the rafter
bracing points below the panel’s centre of being erected should be monitored and
gravity, this needs to be specifically adjusted accordingly.
designed and detailed on the shop As well, substantial inward forces may be
drawings. Special provisions should be imposed on braced panels and fixings to
made to prevent "kick-out" of the base of steelwork as a result of temporarily
the panel in these situations. unrestrained steel rafters rotating and
Regular visual inspection of panels in the moving sideways under self-weight and
braced condition needs to be carried out to erection loads. The resulting forces may
check that the braces and bracing insert overload bracing and fixing inserts.
connections have not been loosened by To ensure safe work methods during the
wind action. erection of steelwork, the project design
A check of the torque of the bolts should engineer should consider the effect of the
be carried out 24 hours after erection and erection sequence on stability in accordance
at appropriate intervals after installation with AS 3828. Clear instructions should be
determined in the erection planning stage provided to the steel erector for the
(see section 8.2 of this code), particularly requirement of any temporary bracing for
after high winds, to ensure the bolts are steelwork. Where such bracing is required it
correctly torqued and the braces have not should be detailed on the shop drawings so
moved. the steel erector can make provision for
such bracing and riggers do not have to
access an unstable structure.

Figure 9.2: Corner bracing

Right Wrong

Floor slab

Floor slab
Wall panel

Deadman

Typically 900 to 1500 mm Deadman Brace Skewed Braces

page

62
 Concrete panel

This illustration
has been
reproduced with
permission from
SAI Global

150mm MIN

300 mm MIN
(Unless otherwise specified) 40mm MAX

Shims

Grout between panel

and footing

Fig 9.3: Levelling shims Footing

9.3 Levelling pads and shims Direct concrete-to-concrete, or concrete-to-

steel bearing should be avoided.
Shims carry the load of the concrete
element which needs to be adequately The gap between the bottom of the
supported to prevent movement until the element and the footing should ultimately
element is incorporated in the main be grouted or dry packed, to transfer the
structure. A levelling pad (mortar bed) or a load to the footings.
level bearing area is used to provide a level
seating for the shims.
9.4 Grouting of the base
See section 4.14.3 regarding horizontal
restraints of concrete panels. After concrete panels have been finally
plumbed, the base of the panel and any
Concrete elements should be designed to grout pockets need to be fully grouted
sit on only two localised shimming points unless otherwise stated on the drawings.
when initially erected. Use of multiple Grouting and appropriate strength gain
shimming points cannot ensure uniform should take place before any formwork is
distribution of load due to difficulties with removed from beams or slabs supported by
construction tolerances. a panel.
Shims should be used on solid foundations The weight of the concrete panel, and any
that are designed to carry the imposed loads applied to it before grouting, will be
loads. applied to the supporting structure at two
Shims should be located at least 300 mm discreet points where the levelling shims
in from the ends of the element and are located.
bearing support, unless otherwise specified.
This is particularly relevant for thin concrete
panels where edge breakout can occur if
shims are placed too close to bottom
corners. See Figure 9.3.
page

63
 Part 10
Incorporation into
final structure
C O N T E N T S

PAGE
10.1 Fixing to final structure .......................................... 65
10.2 Inspection prior to and removal of braces............ 65
page

64
Incorporation into
final structure
10.1 Fixing to final structure 10.2 Inspection prior to and
The fixing of concrete panels should be in removal of braces
accordance with the structural drawings and Panel braces should not be removed until
the shop drawings including any changes the concrete panel is incorporated into the
made to specifications or instructions structure and the structure is capable of
issued by the project design engineer or supporting the panel for the applied loads.
the erection design engineer.
Prior to the removal of braces, the structure
All steelwork forming part of the structure should be inspected to ensure that all
should be erected in accordance with AS structural elements affecting stability are
3828 which sets out recommended safe securely fixed to the panels. This inspection
working provisions and practices supported should be carried out by the project design
by training, for those involved in erection of engineer and written approval to remove
the steelwork including associated trades. the braces given to the builder.
The recommendations also relate to other The removal of braces from a panel should
workers on the site who may be at risk be planned and carried out in a controlled
from the erection of the steelwork. manner to prevent risk of injury and
A key requirement of AS 3828 is the damage to equipment.
preparation of a work method statement by Braces to be removed from site should be
the contractor which clearly identifies the loaded onto transport in such a manner as
method used to erect the steelwork and to allow safe transport and avoid damage
how it will be fitted into the overall to them.
workplan for the project.
Braces should be maintained and inspected
between each use to ensure all components
are correct and in good working order.

page

65
 Appendix A
Definitions of terms used in this code

A1: General ENGINEER PRECAST CONCRETE

ELEMENT
definitions Means a qualified practising
engineer. A qualified A concrete element usually,
BUILDER practising engineer should but not necessarily,
possess an undergraduate manufactured under controlled
The company or person
qualification in engineering conditions in a factory or
responsible for the
and have at least three casting yard and subsequently
construction of the completed
years work experience in transported to and erected on
building and who has control
an engineering field. a building site.
of the building site.
ERECTOR PROJECT DESIGN ENGINEER
BUILDING DESIGNER
The company or person The engineer responsible for
The person responsible for
responsible for erecting the the engineering design of the
the overall design of the
concrete elements. building. The project design
building. The building
engineer should be a
designer will usually be
ERECTION DESIGN ENGINEER qualified practising engineer
responsible to the client.
The engineer responsible for and be competent to practice
CLIENT the design for the erection of in the structural engineering
the concrete elements of the field. The project design
The owner of the building engineer may also be the
building and the stability of
or the company or person erection design engineer.
the concrete elements during
responsible for developing
construction. The erection
the building. SHOP DETAILER
design engineer should be a
CONCRETE ELEMENT qualified practising engineer The person responsible for
and be competent to practice preparing the shop drawings
Either a concrete panel in the structural engineering of the concrete elements.
or other precast concrete field. The erection design The shop detailer should be
element. engineer may also be the a person who, through
project design engineer. training or experience, is
CONCRETE PANEL
able to undertake the work
A concrete panel that is EXCLUSION ZONE as described in this
manufactured as a separate An area over which concrete document.
and movable panel for the elements or other items,
purpose of being incorporated TILT-UP CONCRETE PANEL
while being lifted, are
as a wall (including a suspended or pass over or An essentially flat concrete
retaining wall) once the may fall or drop into. panel designed in accordance
process by which the panel is Workers and members of the with AS 3850 and AS 3600;
manufactured is complete, but public should, as far as cast in a horizontal position,
does not include a column, practicable, be prevented usually on-site; initially lifted
beam or paving slab or a from accessing this area by rotation about one edge
panel that is for decorative while lifting is taking place. until in a vertical or near-
purposes only. vertical position; transported
The panel may be precast PRECASTER and lifted into position if
on-site, or off-site in a The company or person necessary; and then stablized
factory or casting yard. responsible for manufacturing by bracing members until
the concrete elements. incorporated into the final
structure.
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66
TILT-UP WORK CONNECTIONS Deformation controlled
Means any of the following: A method by which one or Anchors that are expanded
more concrete or steel only during installation.
(a) the manufacture,
elements are joined together. Application of further load to
transport, cranage,
The purpose of connections the anchor does not increase
temporary storage,
is to transfer load and/or the expansion force.
erection or temporary
provide stability.
bracing of a concrete This type of anchor is not
panel; permitted in tilt-up and
CRANE RATED CAPACITY
precast construction.
(b) the fixing of a concrete
The maximum load which
panel for the
may be applied to the crane FACE LIFTING
incorporation of the
while in a particular working
panel as a wall (including A method of lifting whereby
configuration and under a
a retaining wall); lifting inserts are cast within
particular condition of use.
the face of a concrete
(c) the removal of temporary
element so that when it is
bracing of a concrete CRANE STANDING AREA
lifted it hangs at an angle to
panel. The base on which the crane the vertical.
is supported during erection
TRANSPORTER
of the concrete elements. FIXING INSERT
The company or person Referred to as the erection
A component cast into or
responsible for transporting platform in AS 3850.
fixed to the concrete
the concrete element.
element and used to tie it
EDGE LIFTING
into the structure.
A method of lifting whereby
A2: Technical lifting inserts are cast within FIXINGS
definitions the concrete element edge
The hardware components of
so that the element is lifted
BRACES all connections including
and hangs vertically from
bolts, washers, weld plates,
Certified temporary that edge.
anchors etc.
components providing
stability in preventing a tilt- EXPANSION ANCHORS
JOINTS
up concrete panel Anchors placed in holes
The gap between adjoining
overturning. Both ends are drilled in hardened concrete
concrete elements or
fitted with a pinned foot, which rely on expansion
between a concrete element
allowing a degree of freedom devices within the hole to
and some other portion of
for variable fixing angles. prevent pullout under load.
the structure.
They are intended to resist The two types of expansion
horizontal construction and anchors are: LEVELLING SHIMS
wind loads. Braces should
Load controlled Proprietary material used
not be used as props.
Anchors that have a wedge under concrete elements to
BRACING FEET OR SHOES and expansion-shield system support them in their correct
where the wedge is directly position until the final
The components that
connected to the applied connection is made.
connect braces onto a panel
or onto the bracing support load. Increases in load
above the retained preload LIFTING BEAM
or footing via pinned
connections and inserts. from the initial torque will A certified component of the
increase the expansion force. rigging system that transfers
BRACING INSERT This type of expansion the load from the concrete
anchor is the only type element to the crane.
A component cast into a
concrete panel or cast into permitted in tilt-up and
or fixed to a brace footing, precast construction.
for later attachment of a
brace.
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67
 LIFTING CLUTCH REINFORCEMENT SHOP DRAWING
A certified proprietary quick- Structural reinforcement A detailed drawing of a
release device used to concrete element used in the
Reinforcement, including
connect the crane rigging to manufacturing and erection
reinforcing steel and
the lifting insert. processes.
prestressing tendons,
provided for the integrity of
LIFTING INSERT STRONGBACK
the completed structure.
A component cast into the A specified temporary steel
Additional reinforcement
concrete element for lifting member fixed to a concrete
it during erection. Reinforcement additional to element to provide localised
the structural reinforcement, strengthening during lifting,
LIFTING SPREADER provided to resist forces transport or erection.
A certified device that caused by transport or
erection loads. TAGLINE OR TAIL ROPE
spreads the lifting ropes and
distributes the lifting load. Component reinforcement A non-conductive line (eg
fibre rope) attached to the
LIMIT STATE FACTOR (LSF) Reinforcement placed in
element being erected to
conjunction with lifting,
The number by which the help control the element
bracing and fixing inserts so
failure load is divided to during lifting and placement.
that they can attain their
give the working load limit design capacities. WLL (WORKING LOAD LIMIT)
(WLL) as referenced in AS
3850. RIGGING SYSTEM The maximum load that may
be applied to an item,
PROPRIETARY COMPONENTS A system of certified re-
component or system.
useable lifting equipment that
Components manufactured in Formerly referred to as the
may include lifting clutches,
a factory environment and safe working load (SWL).
slings, sheaves, lifting or
carrying a trademark or spreader beams or other WORK METHOD STATEMENT
registered name. mechanical devices to
connect the crane to the A document setting out safe
PROGRESSIVE COLLAPSE concrete element being lifted. working procedures.
A continuous sequence of
failures initiated by the local SHEAR CONE FAILURE
failure of one part of the The type of failure reached
structure. when tension is applied to
an insert embedded in
PROPS concrete. When failure
Certified temporary occurs a cone of concrete as
components supporting well as the insert is pulled
loads. Both ends of the prop from the main body of the
are fitted with rigid foot concrete element.
plates that provide support
between two parallel
surfaces. Props should not
be used as braces.
page

68
 Appendix B
Sample documents, schedules and
shop drawing
PROJECT

SITE ADDRESS

CONCRETE PANEL SCHEDULE: PLANNING Sheet 1

Planning Task Action Name Initiation Date Receipt Date

Notification to WorkSafe Western Australia Builder

Commissioner of intention to cast concrete
panels in accordance with AS 3850

Construction programme prepared Builder

Shop drawings prepared Shop Detailer

C.P.S. PROPERTIES completed Builder

Concrete element layout plan showing Builder/

site constraints, stacking sequence, Site Manager/
crane position/s, erection sequence and Erector
temporary brace position

Shop drawings and layout plan marked Erection Design

up and signed by engineer Engineer

Approved shop drawings checked for Project Design

structural intent by engineer Engineer

Work Method Statement: Site Manager

SITE ESTABLISHMENT/SERVICES

Work Method Statement: Site Manager

CONCRETE ELEMENT PRODUCTION

Work Method Statement: Erector

CONCRETE ELEMENT ERECTION

Work Method Statement: Erector

STEEL INCORPORATION INTO
FINAL STRUCTURE

Local Government Authority Building Licence Builder

Reinforcement scheduled from approved Builder

shop drawings

C.P.S. HARDWARE completed Builder

Panel casting sequence programmed from Site Manager

construction programme and layout plan

Workplan Master File: Builder

page

PLANNING/PRODUCTION/ERECTION
69
HOLD POINT
Concrete element production must not commence until all planning requirements are satisfied
 Sheet 2

This illustration has

been reproduced from
the Concrete Panel
Buildings Briefing
08 January 2003 with
permission of Cement
Concrete & Aggregates
Australia
page

70
PROJECT

SITE ADDRESS

CONCRETE PANEL SCHEDULE: PROPERTIES Sheet 3

DESIGN ENGINEER

REVISION DATE

Panel Length Height Thickness Gross Openings Nett Perimeter Volume Tonnes
# (mm) (mm) (mm) (m2) (m2) (m2) (mm) (m3)

TOTALS:
page

71
 PROJECT

SITE ADDRESS

CONCRETE PANEL SCHEDULE: PROPERTIES Sheet 4

HOLD POINT
Concrete element production must not commence until all the planning requirements are satisfied

Production Task Action Name Completion

Date
Audit all panel components against Site Manager
C.P.S. HARDWARE are on site
Audit scheduled reinforcement and “shake out” Site Manager
into individual panels
Set out casting beds in accordance with Site Manager
concrete element layout plan
Provide compacted limestone (or alternative) Site Manager
access ramps and slab edge protection for
concrete agitator trucks

KEEP ELECTRIC LEADS CLEAR OF ALL VEHICLE ACCESSWAYS

START concrete element production in accordance

with panel casting programme and Site Manager
C.P.S. QUALITY CONTROL
Maintain daily concrete delivery and test records for Site Manager
C.P.S. QUALITY CONTROL (test as per AS 1379)
Set out and permanently mark panel positions on footings. Site Manager
Verify dimensions “close-out” with layout plan
Clearly mark panel level pad positions on footings and Site Manager
record pad thicknesses on concrete element layout plan

MAINTAIN STRICT HOUSEKEEPING AND CLEANLINESS POLICY

C.P.S. QUALITY CONTROL completed, test results Site Manager

recorded and completed
Strip formwork, cleanup, remove from erection area. Site Manager
Clearly mark panel number on panel base
Audit temporary strongbacks and falsework delivered in Site Manager
accordance with shop drawings and layout plan
Audit temporary brace insert bolts with 20mm Site Manager
galv. structural and spring washer assembly
Audit temporary brace torque controlled floor anchors Site Manager
with 20mm galv. structural washer assembly

HOLD POINT
Concrete element erection must not commence until all the
production requirements are satisfied
page

72
PROJECT

SITE ADDRESS

CONCRETE PANEL SCHEDULE: QUALITY CONTROL* Sheet 5

*to be completed with signed/certified shop drawing

DESIGN ENGINEER

Panel Revision Bond- Dimen Reinf. Hardw. Services Poured Mpa Test
# breaker (mm) Sched Sched Sched
Certified 1st 2nd 3rd 4d./7d.

PANEL QUALITY SUPERVISED BY:

This is to certify that the above listed concrete
elements have been manufactured in accordance
INSPECTED & RECORDED BY: with the approved shop drawings.

Name:
AUTHORISED TO LIFT BY:
Signature:

Date:
Date:
page

73
 SITE ADDRESS

DATE

CONCRETE PANEL SCHEDULE: ERECTION Sheet 6

HOLD POINT
Concrete element erection must not commence until all the
production requirements are satisfied

Erection Task Action Name Completion

Date
Provide compacted limestone (or alternative) access ramps Site Manager
and slab edge protection for crane
Identify and clearly mark any U/ground services in Site Manager/
“angle of repose” vicinity of crane standing area Erector
Traffic management plan approved with valid permits Site Manager/
and/or personnel deployed in accordance with Erector
Work Method Statement: CONCRETE ELEMENT ERECTION
Erection and fall zones are warning barricaded from Site Manager/
unauthorised entry and from public safety Erector
Crane supplied is of capacity planned in layout plan and Site Manager/
in approved service condition Erector
Rigging equipment and hardware of capacity as approved Erector
on shop drawings, layout plan and Work Method Statement
Crane and rigging personnel demonstrate technical Site Manager/
competencies and complete site induction Erector
All erection personnel have participated and “signed off” Erector
the JOB SAFETY ANALYSIS
Correct diameter drill-bits/adequate sized rotary hammer Erector
drills, at least 3 suitable panel bars, rotary socket wrenches
and manual torque socket wrench

KEEP ELECTRIC LEADS CLEAR OF ALL CONCRETE ELEMENTS BEING ERECTED

Temporary bracing anchors to be torque “preloaded” on Erector

installation ONLY and recorded on C.P.S. TORQUE REGISTER
All concrete elements to be aligned, base restrained, Erector
in plumb and temporary bracing anchors to be checked
for “slip-load” (70%) preload

HOLD POINT
Incorporation of structural steel into final structure must not commence until all the
concrete element erection requirements are satisfied
page

74
PROJECT

SITE ADDRESS

DATE

STRUCTURAL STEEL INCORPORATION INTO FINAL STRUCTURE Sheet 7

HOLD POINT
Incorporation of structural steel into final structure must not commence until all the
concrete element erection requirements are satisfied

Structural Steel Erection Task Action Name Completion

Date
Provide compacted limestone (or alternative) Site Manager
access ramps and slab edge protection for
crane and EWP
Identify and clearly mark any U/Ground services Site Manager/
in “angle of repose” vicinity of crane standing area Erector
Identify and clearly mark any slab penetrations and Site Manager/
concrete element temporary bracing obstructions Erector
affecting EWP and crane mobility
Traffic management plan approved with valid Site Manager/
permits and/or personnel deployed in accordance Erector
with Work Method Statement: STRUCTURAL
STEEL INCORPORATION INTO FINAL STRUCTURE
Erection and fall zones are warning barricaded Site Manager/
from unauthorised entry and for public safety Erector
Structural steel fabricated and delivered to site Site Manager/
is in accordance with shop drawings, structural Erector
steel layout plan and Work Method Statement
Crane, EWP and rigging personnel demonstrate Site Manager/
technical competencies and complete site induction Erector
All erection personnel have participated and Erector
“signed off” the JOB SAFETY ANALYSIS
Fall prevention systems are recognised, maintained Erector
and monitored throughout structural steel erection
On completion of erection of structural steel the Project Design
entire structure inspected for structural compliance Engineer

HOLD POINT
Concrete element temporary bracing removal and loading of roofing material and/or plant
onto structural steel must not commence until structure is inspected and written approval
of compliance by project design engineer.

Record concrete element temporary bracing Site Manager

removal on C.P.S.TORQUE REGISTER
page

75
 PROJECT

SITE ADDRESS

CONCRETE PANEL SCHEDULE:

TEMPORARY BRACE LENGTH/TORQUE REGISTER Sheet 8
ERECTION DESIGN ENGINEER

PROJECT DESIGN ENGINEER

RIGGING CONTRACTOR

Panel Brace Preload Slipload Remark Brace Preload Slipload Remark Insp/ Release
# ‘A’ ‘B’ Cert

TORQUE PRELOAD ONCE ONLY

STRUCTURAL INTEGRITY INSPECTED/APPROVED BY:

page

76
 Appendix C
Referenced documents
and further reading

Legislation referenced
• Occupational Safety and Health Act 1984
• Occupational Safety and Health Regulations 1996
• Building Regulations 1989

Publications referenced
Commission for Occupational Safety and Health
• Guidance Note: General Duty of Care in Western Australian Workplaces
• Codes of Practice: First Aid Facilities and Services, Workplace Amenities and Facilities,
Personal Protective Clothing and Equipment
• Code of Practice: Prevention of Falls at Workplaces

WorkSafe
• Guidelines for Work in the Vicinity of Overhead Power Lines

Australian Standards
• AS 1012 Methods of testing concrete
• AS/NZS 1170.0 Structural design actions – General principles
• AS/NZS 1170.1 Structural design actions – Permanent, imposed and other actions
• AS/NZS 1170.2 Structural design actions – Wind actions
• AS/NZS 1170.4 Minimum design loads on structures – Earthquake loads
• AS 1379 Specification and supply of concrete
• AS 1418 Cranes (including hoists and winches)
• AS 2550 Cranes- Safe use
• AS 3600 Concrete structures
• AS 3610 Formwork for concrete
• AS 3799 Liquid membrane-forming curing compounds for concrete
• AS 3828 Guidelines for the erection of building steelwork
• AS 3850 Tilt-up concrete construction
• AS 4100 Steel structures
page

77
 Other documents referenced Further reading, advice and
• Building Code of Australia, published by information
the Australian Building Codes Board. Additional and more detailed information can
The Building Code of Australia 96 (BCA96) be obtained from the above organisations
is a uniform set of technical provisions for and their websites and some of these
the design and construction of buildings documents are listed below.
and other structures throughout Australia. Cement & Concrete Association of Australia
It allows for variations in climate and
geological or geographic conditions. The • Tilt-up Construction Notes
BCA is produced and maintained by the • Briefing Notes (monthly publication)
Australian Building Codes Board (ABCB) on
behalf of the Commonwealth Government National Precast Concrete Association
and each State and Territory Government. of Australia
The BCA96 is available as a stand-alone
• National Precaster (Newsletter)
product or with value-added products
included. The stand-alone versions are In addition to the above organisations and
available from the ABCB’s Principal publications, manufacturers of hardware,
Publishers, Standards and CanPrint, in including drilled-in inserts, associated with
electronic and hard copy formats. the precast and tilt-up concrete industries
all publish design and technical information
• Z48: Precast Concrete Handbook,
on their products. Reference should be
produced by the National Precast
made by designers and users to the
Concrete Association of Australia and
particular supplier's technical information
published by the Concrete Institute of
for advice before specifying or using any of
Australia.
their products.
• Z10: Recommended Practice, Design of
Tilt-up Concrete Wall Panels, published
by the Concrete Institute of Australia.
page

78