Professional Documents
Culture Documents
Information on the key changes introduced by the OHS 2017 Regulations can be
found in the guidance titled Occupational Health and Safety Regulations 2017:
Summary of changes - available at https://www.worksafe.vic.gov.au/__data/
assets/pdf_file/0011/207659/ISBN-OHS-regulations-summary-of-
changes-2017-04.pdf. However, this guidance document contains material of a
general nature only and is not to be used as a substitute for obtaining legal advice.
Developing the standard in partnership
Foundations for Safety has brought together State Government regulatory agencies, accident
research expertise, construction industry trade unions and employer associations representing
principal contractors and construction sub-contractors. It meets in full session every three months
and establishes working parties to progress various health and safety initiatives.
At the time of printing, the organisations represented on Foundations for Safety are:
• Australian Industry Group
• Australian Manufacturing Workers Union
• Air Conditioning and Mechanical Contractors Association
• Civil Contractors Federation
• CEPU Electrical Trades Union
• CEPU Plumbing Division
• CFMEU Construction and General Division
• CFMEU FEDFA Division
• Finishing Trades Association of Australia
• Housing Industry Association
• Master Builders Association of Victoria
• Master Plumbers & Mechanical Services Association of Australia
• Monash University Accident Research Centre
• National Electrical and Communications Association
• Office of the Chief Electrical Inspector
• Victorian Employers Chamber of Commerce and Industry
• Victorian Trades Hall Council
• Victorian WorkCover Authority
You can help improve health and safety in the construction industry by providing your
feedback on this Industry Standard or on other health and safety issues to any of the
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Part 5: Manufacture................................................... 31
5.1 Pre-planning ................................................................................. 31
5.2 Shop drawings ............................................................................... 31
5.3 Casting and erection sequences ........................................................... 31
5.4 Formwork .................................................................................... 33
5.5 Tolerances .................................................................................... 33
5.6 Reinforcement................................................................................ 34
5.7 Lifting inserts................................................................................. 34
5.8 Strongbacks .................................................................................. 35
5.9 Concrete placement ......................................................................... 35
5.10 Minimum strength for lifting ............................................................... 36
5.11 Curing and release ........................................................................... 36
5.12 Special provisions for on-site casting..................................................... 36
5.13 Release agents ............................................................................... 37
5.14 Stripping and repair ......................................................................... 37
5.15 Modification .................................................................................. 37
5.16 Element identification ....................................................................... 37
5.17 Manufacturer’s certificate of compliance ................................................. 37
Contents cont.
Appendices
A: Referenced documents and further reading.............................................. 69
B: Definitions of terms used in this Industry Standard .................................... 72
C: Erection design engineer’s certificate of compliance.................................... 76
D: Manufacturer’s certificate of compliance ................................................. 77
Illustrations
3.1 Threaded inserts ............................................................................. 11
3.2 Grout tube .................................................................................... 13
4.1 Wall panel rigging............................................................................ 20
4.2 Shear loads and tension loads in edge-lifted panels .................................... 23
4.3 Panel rotation................................................................................. 24
4.4 Panel bracing ................................................................................. 27
5.1 Crane lifting radius........................................................................... 32
8.1 Clearance for cranes from overhead power lines ........................................ 48
8.2 High voltage contact......................................................................... 50
8.3 Tailing lifters .................................................................................. 54
8.4 Levelling shims .............................................................................. 58
8.5 Uneven erection loading .................................................................... 62
Introduction
Precast concrete construction is a method This Industry Standard is based on current
of prefabricating concrete in discrete knowledge and construction methods
elements and erecting and incorporating within the industry and is not intended to
them by crane into their final position in exclude other methods or processes that
the building structure. can be shown to meet the requirements of
providing a safe workplace.
This document sets out industry-wide
guidelines for establishing and maintaining The August 2000 draft of this Standard
a safe working environment wherever was prepared by a committee comprising
precast and tilt-up concrete construction representatives from the building industry,
is used. industrial unions and WorkCover.
1
Part 1: General cont.
2
Part 2:
Training and hazard management
2.1 General • keep abreast of the current state of
knowledge within the industry on the
A principal objective of Victoria’s
means of eliminating hazards and
Occupational Health and Safety Act 1985 is
controlling risks to health and safety.
to provide a safe working environment and
to prevent harm to employees at work. To 2.2 Training
do this, it imposes duties of care on
employers, employees, and others, and Employees need to work safely. They must
requires employers and employees to be trained and instructed in safe systems
cooperate in ensuring that workplaces and of work and safe work practices.
work practices are safe and without risks Employers must ensure an appropriately
to health. experienced person maintains close
One of the employer’s primary obligations supervision of employees who are not yet
under the Act is to provide: sufficiently skilled and experienced to
“such information, instruction, training carry out their work safely.
and supervision to employees as are Training programs should emphasise
necessary to enable the employees to occupational health and safety and should
perform their work in a manner that is safe provide opportunities for individuals to
and without risks to health.” have their existing skills recognised and to
[section 21 (2) (e)] develop new knowledge and skills.
Employers owe this same duty of care to Education and training programs should
independent contractors and their be structured to lead to nationally
employees working at the workplace. recognised qualifications and should be
delivered by a registered training
In fulfilling this obligation, the precast organisation. Such training should be in
concrete industry should maintain a addition to and not replace the
structured system of education and requirement for site-specific induction.
training to enable both employers and
employees to:
• identify and manage the risks involved in
the manufacture, transportation and
erection of precast concrete and tilt-up
3
concrete elements
Part 2: Training and hazard management cont.
Training and instruction programs should Employers have a general duty to ensure
include: the health and safety of employees while at
• induction on this Industry Standard work. In particular they must take all
practicable steps to:
• occupational health and safety (OHS)
training to the industry competency • provide and maintain a safe working
standard as defined by the National environment
Building and Construction Industry • provide and maintain facilities for the
Training Board, Construction Training safety, health and welfare of employees
Australia • ensure that machinery and equipment is
• first aid training to the minimum designed, made, set up, and maintained
requirements of WorkCover’s Code of to be safe for employees
Practice for First Aid in the Workplace • ensure that employees are protected
• supervised practical experience from hazards in the course of their work
programs specific to the tasks being • provide procedures to deal with
performed by the employee. Such emergencies that may arise while
training should be complementary to, or employees are at work
part of, a program leading to a national
Before commencing work on a project,
qualification
employees must be informed by their
• identification of hazards associated with
employer of:
the use of plant and equipment
• emergency procedures
• the selection, care and use of protective
• hazards they may be exposed to while at
clothing and equipment
work
2.3 Health and safety • hazards they may create while at work
that could harm other people
Employers should ensure that all
employees have the opportunity to be fully • how to minimise the likelihood of
involved in the development of procedures hazards becoming a source of harm to
including hazard identification, themselves and others
assessment of risk and control of risk • the location and correct use of safety
methodology. equipment
4
Part 2: Training and hazard management cont.
Employers must inform employees of the should personnel stand below or work on
results of any health and safety an element that is leaning towards them.
monitoring.
Although component failure is rare the
Employers are also responsible for the consequences are always significant.
health and safety of people who are not
To ensure appropriate hazard
employees. Employers must take all
management, an assessment of the risks
practicable steps to ensure that employees
must be carried out by the builder in
do not harm any other person while at
conjunction with the health and safety
work, including members of the public or
representatives of the contractors and
visitors to the workplace.
workers involved in the work.
Employees are responsible for their own
A job safety analysis that lists the hazards
safety and health while at work and must
and suggests safety procedures should
also ensure that their actions do not harm
also be prepared. The minimum
or place others at risk. They must
requirements for this job safety analysis
cooperate with their employer on health
include:
and safety matters and must not interfere
• an identification of the hazards
with or misuse anything provided by their
employer to protect health and safety. • an assessment of the risks from the
hazards identified
2.4 Hazard management • control measures required to eliminate
Employers must have in place an effective or minimise the risks from the hazards
method to identify hazards and to • identification of the person responsible
determine whether there are significant for implementing and monitoring the
hazards that require further action. A control measures
hazard is an existing, new or potential Where possible, the hazard should be
situation or event that could jeopardise the eliminated or the risk reduced by changing
safe and healthy working environment. or modifying the proposed work method,
In the precast and tilt-up concrete construction method, or by use of
industry, risk is always present when alternative equipment.
handling, transporting and erecting
elements. Under no circumstances 5
Part 2: Training and hazard management cont.
6
Part 3:
General design provisions
3.1 General Special care should be taken in design and
In precast concrete construction, there are during construction to guard against
two separate phases of design. progressive collapse.
The first, the structural design, is for the Progressive collapse means a continuous
in-service condition and is usually carried sequence of failures initiated by the local
out by the project design engineer as part failure of one part of the structure. Precast
of the design of the complete structure. concrete structures are susceptible to this
type of failure.
The second, the design for erection, is for
the handling, transportation and erection Progressive collapse may be prevented by
of the individual elements and structure providing either:
during the erection process. It may be • adequate structural strength and
carried out independently of the structural continuity of the structure and its parts
design by the project design engineer or • alternative load paths that cause applied
by the erection design engineer. forces to be safely transmitted through
The structural design should be carried out the structure
by a designer experienced in the field of The failure of a single member should not
precast concrete construction and who is a lead to the complete collapse of the
registered building practitioner in structure. This is particularly important
accordance with the requirements of the where structural stability is provided by
Building Act 1993. steel roof-bracing systems.
The structural design should take into
account the particular requirements of 3.3 Specification of concrete
precast concrete structures to ensure that The concrete specification should be
the elements can be erected. clearly shown on the drawings and include
any special requirements, for example,
3.2 Building stability colour, cement content and water-cement
The stability of the whole building should ratio.
be checked by the project design engineer
or the erection design engineer at each
stage during erection and under in-service
7
load conditions.
Part 3: General design provisions cont.
8
Part 3: General design provisions cont.
For concrete wall panels, the thickness When selecting joint filling materials,
should be determined by limiting the consideration should be given to:
extreme fibre tensile stresses so that the • thermal and shrinkage movement of the
section remains “uncracked”. Appropriate element
reinforcement should then be determined
• fire resistance level
by using a cracked-section analysis. 9
Part 3: General design provisions cont.
Where specific roughness is required on For all drilled-in expansion anchors the
the surface of the precast element to ultimate capacity should be determined in
provide a key for the insitu concrete, this accordance with AS 3850.
should be clearly specified on the
10 drawings.
Part 3: General design provisions cont.
12
Part 3: General design provisions cont.
Reinforcement cut
around grout tube
Bottom of as necessary
wall panel
Grout tube
Additional reinforcement
each side of grout tube
3.11 Tolerances
Recommended tolerances are given in part Where required tolerances are less than
5 and should be taken into consideration in the recommended values given in part 5,
the design. the specific requirements should be clearly
stated on the drawings.
Because precast and tilt-up concrete
elements cannot be manufactured to exact
dimensions, provision should be made in 13
the design for dimensional variation.
Part 3: General design provisions cont.
14
Part 4:
Design for erection
4.1 General 4.2 Planning
This section provides specifications for the Prior to preparation of the shop drawings,
design of the precast elements to ensure the parties involved in the design,
that they resist the forces to which they manufacture, transport and erection
will be subjected during handling, process should liaise to plan the complete
transportation and erection. construction and erection sequences.
Consideration should be given to details
Shop drawings should be prepared for
such as site limitations, local street
each element and should incorporate all of
access, delivery sequence, transport
the details and requirements for the
requirements, and overhead obstructions.
handling, transportation and erection
These aspects can have a significant effect
requirements.
on the size of precast elements and on the
Shop drawings are normally the erection process.
responsibility of the precaster.
4.3 Shop drawings
As part of the structural design process,
the project design engineer must provide Where possible, the orientation of the
sufficient details to allow the shop detailer elements on the shop drawings should be
to prepare shop drawings and the erection the same as the proposed casting
design engineer to prepare the erection orientation, i.e. the shop drawing should
design. view the element as set out on the casting
bed.
The shop drawings and erection design
should be submitted to the project design Shop drawings must include the following:
engineer for review to ensure that they • date and issue number of the drawing
comply with the requirements of the • project location
structural design.
• element number
• the mass of each element
15
Part 4: Design for erection cont.
• the size, configuration and cover of any • requirements for erection brace
additional reinforcement required for the footings, brace fixings and concrete
transport and lifting of the element strength of footing at time of erection
16
Part 4: Design for erection cont.
18
Part 4: Design for erection cont.
19
Part 4: Design for erection cont.
Minimum
3C + D
Minimum 2D
Minimum
C + 300mm
C
8
*
C
D
D
4x1
2x1 2x2
Minimum 2D
Edge lift
D
E
Minimum 3D
4x2
2x4
21
Part 4: Design for erection cont.
Lifting inserts should be positioned to When selecting a lifting insert, ensure that
ensure that after casting, the following the nominated capacity from the
information is still visible: manufacturer’s catalogue is for the
direction of the load being applied.
• the insert manufacturer’s symbol or
name All lifting inserts require adequate
• the lifting capacity of the insert embedment or anchorage to function
effectively. Anchorage is affected by:
• the insert length
• proximity to edges
Lifting inserts must be designed,
• proximity to holes, recesses or edge
manufactured and installed to provide a
rebates
working load limit (WLL) with a design
factor of at least 2.5 against concrete • proximity to other loaded lifting devices
failure. In determining this, the applied • concrete thickness
load should include the mass of the • concrete strength at lifting
element as well as suction and impact load • embedment depth
due to lifting.
• the presence of cracks
Lifting inserts should be installed in • the proximity of reinforcement or
accordance with the manufacturer’s pre-stressing tendons
instructions. Particular care must be
exercised when inserts require tying to Horizontal bars placed around the foot of
reinforcement, or where component a lifting insert may provide very little
reinforcement or special reinforcing additional lifting capacity to the insert.
elements are required for the proper
22
installation of lifting inserts.
Part 4: Design for erection cont.
When fixed length multi-legged slings are Where prestressing strand is used as
to be used for lifting precast elements, any a lifting loop, it must comply with the
two of the lifting inserts must be capable requirements of AS 1311.
of supporting the total load.
Edge lifter
Edge lifter
TENSION LOAD
23
Part 4: Design for erection cont.
Rigging to
um main hoist
axim
dm
Rigging to nde : 60
tailing hoist m me ss
o e
Rec /thickn
n
spa
Th
ick
ne
ss Precast wall panel
24
Part 4: Design for erection cont.
The bracing foot or shoes should be made to prevent “kick-out” of the base of
designed to prevent lateral displacement of the element.
the shoe from the fixing insert after
Where brace angles are outside the range
installation.
of 45–60 degrees to the horizontal, design
Two braces or props may not be necessary computations must be prepared to verify
where precast or tilt-up concrete elements brace, brace fixing and brace footing
are provided with erection brackets or capacities (see figure 4.4).
permanent connections to other restrained
For face-lifted wall panels, bracing inserts
elements such as steel portal columns or
should be on the same face of the panel as
walls forming a stable “box” structure.
the lifting inserts. This is to ensure that
Where single braces are used, they should personnel are not required to fix a brace to
be clearly specified on the shop drawings a wall panel that is leaning towards them.
and have a minimum of two fixings at each
Props supporting precast concrete floor
end.
units should have rigid saddles to support
Where single braces are used, particular the top bearer. The top bearer should be
care is required on site to prevent any located in the saddle in such a way as to
damage that could be caused by impact or prevent rolling of the bearer and to ensure
failure of the brace or fixing insert. that the load is transferred concentrically
into the prop. Where bearers are lapped
A brace connected to one element must
over a prop, the capacity of the prop must
never be connected to another element for
be sufficient to resist eccentricity due to
support, unless this is clearly specified on
loading on one side only.
the shop drawings.
Precast and tilt-up concrete elements must
The ideal location of bracing points in a
remain braced or propped until they are
wall panel is at two-thirds of the height,
adequately restrained or incorporated into
measured from the base of the panel.
the final structure.
Where it is necessary to locate bracing
points below the element’s centre of Braces must be maintained and inspected
gravity, this should be specifically between each use to ensure that all
designed and detailed on the shop components are correct and in good
drawings. Special provisions should be working order.
26
Part 4: Design for erection cont.
Required capacity of
Panel height
brace to be nominated
on shop drawings
typically 2/3 panel height
Type of fixing to be
nominated on shop
drawings
Floor slab
45-60°
individually proof tested to the working When designing bracing inserts for
load limit. footings, the strength of the concrete in
the brace footing must be considered.
Deformation-controlled anchors, including
Bracing footings are frequently cast only a
self-drilling anchors and drop-in (setting)
few days prior to erecting the precast
impact anchors, must not be used.
elements. Concrete strength required in
Bracing insert capacities are sensitive to: the brace footing at the time of erection
• the method of installation must be clearly specified on the shop
drawings.
• the strength of the concrete into which
they are placed Further information is given in
WorkCover’s Guidance Note, Use of
• the distance from the insert to the edge
Anchors as Bracing Inserts in Precast
of the element
Concrete Panels.
Unless expressly designed and clearly
specified, no bracing insert should be 4.13 Brace footings
closer than 300 mm to the edge of the
Brace footings should be designed to
element or the bracing support.
resist all expected loads, including:
Substitution of anchor or insert types and • construction loads
manufacture must not be made without • wind loads for temporary structures in
the written approval of the shop detailer or accordance with AS 1170.2
the erection design engineer.
Brace footing requirements and details for
Bracing insert requirements and details for each type of precast or tilt-up concrete
each type of precast or tilt-up concrete element must be clearly specified on the
element must be shown on the shop shop drawings. This must include the
drawings. required concrete strength at the time of
installation of the bracing.
Bracing inserts should be located to allow
the braces to hang vertically without Unless specifically designated otherwise,
interfering with the lifting rigging. A the concrete strength of the brace footing
minimum horizontal displacement of at the time of installation of the bracing
200 mm for the bracing insert from the must be at least 20 MPa.
28 vertical line of the lifting inserts will
Written confirmation of the required
normally be adequate. concrete strength of the brace footing
Part 4: Design for erection cont.
The likely concrete strength at the time of • a general description of the erection
erection should be considered in the process, identifying the objectives of the
design of the brace footing. erection process and broadly describing
how these objectives are to be realised
The ends of braces must be fixed to a
solid, flat concrete or other surface that is • a statement identifying who will be
capable of resisting the applied loads. responsible on site for each phase of the
erection process
4.14 Special provisions • a risk analysis to identify critical
This section sets out additional activities involved in the erection and a
requirements that apply in the case of clear statement describing how the risks
buildings, or portions of buildings: in each activity are to be eliminated or
minimised
• greater than one panel in height
• design computations prepared by a
• incorporating wall panels greater than
registered building practitioner who is a
8 m in height
suitably qualified and experienced
• incorporating wall panels weighing more
engineer.
than 8 t
These computations should be based on
• incorporating wall panels which are not
the requirements of the relevant
nominally flat or rectangular
Australian Standards and should
• where wall panels are not directly fixed
confirm the stability of the structure
and supported by a free-standing 29
structural frame
Part 4: Design for erection cont.
30
Part 5:
Manufacture
5.1 Pre-planning 5.3 Casting and erection
sequences
Prior to manufacturing the precast
elements, the parties involved in the The casting and erection sequences of the
design, manufacture transport and precast or tilt-up concrete elements should
erection process should liaise and have be agreed between the builder, precaster,
planned the complete construction and erector and, where necessary, the erection
erection sequences. Factors that need to design engineer and/or project design
be taken into account in this process engineer. The precaster, in association with
include: the builder and erector, should prepare
• site limitations and local street access plans showing the erection sequence and
bracing layout in accordance with the
• panel size
requirements of part 4.
• crane size, configuration, mobility and
access The casting and erection sequences
should take into account the required
• delivery sequence
crane capacity and configuration.
• transport requirements
When assessing crane requirements, note
• overhead obstructions, especially tram
that:
or train wires, overhead power lines and
construction site overhead power • a crane’s rated capacity refers to its
capacity at a minimum radius and often
5.2 Shop drawings bears little relation to its actual capacity
The precaster should provide detailed to lift large panels
shop drawings of each precast or tilt-up • the selection of crane size must be made
concrete element in accordance with the with consideration to the working radius
requirements of part 4. and boom extension required
• for face-lifted wall panels, assessment of For tilt-up panels, the casting sequence
the true working radius of the crane should reflect the erection sequence.
should be made by adding at least 1.5 m
To avoid multiple handling with stack-cast
to the final panel position radius. This
tilt-up panels, the top panel should be
may need to be increased for tall panels
erected first.
(see figure 5.1)
Rotation
32
Part 5: Manufacture cont.
The shop detailer or the erection design The concrete supplier should be advised
engineer should approve any changes to of:
the specified strongback system. The shop • the specified characteristic concrete
drawings should be amended accordingly. compressive strength
• the concrete compressive strength
5.9 Concrete placement
required at time of lifting
Prior to placing concrete, the arrangement • the maximum aggregate size
must be inspected for compliance with the
• the slump
shop drawings. In particular, this must
include checks on: • special design requirements, if any, e.g.
colour, cement content and water to
• formwork dimensions
cement ratio
• formwork stability
• the site access, required rate of supply
• edge details and penetrations and the method of placement, e.g. type
• connection details of pump
• insert locations, types and fixing to Vibrators should be used to compact the
reinforcement concrete. Particular attention and care
• reinforcement sizes, locations and fixing should be paid to vibrating the concrete
• bond-breaker effectiveness around the inserts and adjacent to the
corners and edges. Concrete must be
The inspection should be carried out by a
placed in a uniform manner and properly
trained and competent person who was
spread over the area before commencing
not involved in the original set-up. For
vibration.
stack casting, an inspection should be
done prior to the casting of each panel.
35
Part 5: Manufacture cont.
The strength, watertightness and durability To ensure that personnel are not required
of concrete depend on the concrete being to fix a brace to a wall panel that is leaning
adequately cured. towards them, bracing inserts should be
on the same face of the panel as the lifting
Release agents used in the manufacture of inserts.
precast or tilt-up concrete elements should
36
be checked for compatibility with the
Part 5: Manufacture cont.
38
Part 6: Handling and storage cont.
39
Part 6: Handling and storage cont.
41
Part 7:
Transport
7.1 General 7.2 Basic principles
Secure restraint of loads on vehicles is Before the shop drawings are prepared,
important in preventing accidents and element sizes and transportability should
injuries. be reviewed to confirm that the proposed
elements are able to be transported to the
The transporter must ensure that any load
building site and be erected. The feasibility
is securely restrained. This means that the
of transporting a crane of the required type
load:
and capacity to lift the elements also needs
• must not be placed in a way that makes
to be taken into account. The precaster
the vehicle unsafe or unstable
must ensure that the concrete strength of
• must be secured so that it is unlikely to the precast elements has reached the
fall or be dislodged from the vehicle and design strength for transport and erection.
• must be restrained by an appropriate
The precaster must ensure that the
method
elements are loaded in a sequence
Methods of restraint should comply with compatible with the required unloading
the VicRoads publications Load Restraint sequence on site.
Guide, Section D: A Guide to Restraining
Precast components should not be
Concrete Panels. These guides describe
transported within three days of casting
the performance standards that any
unless concrete in the specific
restraints must meet and provide
components is tested to confirm that
information on the principles of
design strength for erection has been
restraining, requirements for positioning,
attained. These test results must be
and how to secure loads.
available on site prior to erecting the
The adequacy of a particular method of element.
restraint will depend on the type of
The transporter must ensure that the
element being transported and the type of
vehicle used is suitable to transport the
vehicle being used.
elements and that they are properly
secured. A vehicle must never be moved
without the load being secured in the
appropriate manner.
42
Part 7: Transport cont.
The transporter must ensure that drivers Restraint equipment and anchor points
have been adequately instructed in the safe must be strong enough to hold the load.
transportation of precast elements, with The equipment should be inspected before
particular attention given to: use to ensure that it is serviceable.
• power lines Elements should be loaded so that
• tram lines identification marks are visible during
• train lines unloading.
• OD routes (recognised truck routes for Drivers should stop and check the load
over dimensional loads) and the restraints shortly after
• roundabouts and “reverse camber in the commencing the journey to ensure that
road” the load has not moved or settled.
44
Part 7: Transport cont.
The transporter should inspect the site Under no circumstances should a vehicle
prior to entry to verify that there are no be moved without the load being secured
dangers such as backfilled excavations or in the appropriate manner. The transporter
overhead services. The area to receive the is responsible to ensure that the load is
delivery vehicle should be firm and level. secured in the appropriate manner at all
times, even during the unloading
The transporter must position the vehicle
operation.
as directed by the erector and stabilise the
vehicle prior to releasing the element
restraints. Semi-trailers should be
stabilised by lowering the support legs
onto a firm base. The transporter should
be aware of which elements are to be
unloaded first.
45
Part 8:
Erection
8.1 General The planning process should ensure the
on-site provision of:
Safe erection of precast and tilt-up
concrete elements depends on the pre- • adequate and hygienic amenities for the
planning process. All personnel should be erection crew in accordance with
aware that erection of any precast element WorkCover’s Code of Practice for
is potentially hazardous and that the Building and Construction Workplaces
purpose of the pre-planning process is to or the WorkCover Safety Guidance Note
identify hazards and control any risk in the Amenities for Housing Construction
erection process. Although the risks may (Cottage Industry) Sites, as appropriate
be small, the consequences of a failure can • adequate site access for the type of
be death, serious injury or damage to the construction methods to be employed
building or equipment. • adequate access for the size of the crane
to be used
8.2 Planning the construction
• adequate access for semi trailers
and erection sequence
• serviceable height access equipment
Prior to manufacturing the precast appropriate to the construction methods
elements, the precaster and the erector in
association with the project design 8.3 Planning cranage
engineer and the builder, should have requirements
planned the complete construction and
Cranes and elevating work platforms
erection sequences.
should be selected and used in accordance
The planning process should take into with the appropriate parts of AS 2550.
account:
Cranage planning should commence as
• site limitations early as possible in development of the
• local street access work or project. In the case of new
• element sizes buildings or structures, architects,
designers and engineers should give
• crane size, mobility and access
consideration to crane loadings and
• casting sequence access at the initial design stage,
• overhead obstructions, including especially where methods such as tilt-up
46 overhead power lines
Part 8: Erection cont.
construction are contemplated and where • the make-up of the rigging crew
cranes may be supported on concrete appropriate to the particular
slabs. circumstances of the job
47
Part 8: Erection cont.
NO GO ZONE
Spotter Anywhere above Spotter
required Power Line required
between between
3 - 6.4m
and 3 - 6.4m
of within 3m each side of
Power Power
Lines See special provisions Lines
Open Open
area area
outside outside
6.4m 3m 3m 6.4m
of of
Power Power
Lines Lines
NO GO ZONE
Spotter Anywhere above Spotter
required Power Line required
between between
8 - 10m
and 8 - 10m
of within 8m each side of
Power Power
Lines See special provisions Lines
Open Open
area area
outside outside
10m 10m
of 8m 8m of
Power Power
Lines Lines
• when moving away from the crane, Following any contact with live power
shuffle or hop slowly across the affected lines, a competent person should inspect
area. Large steps should be avoided as the crane for possible damage caused by
one foot could be in a higher voltage the contact before further use. Wire rope
area and the other in a lower voltage should be replaced if it touches the power
area. Under some circumstances, the line as the arc will usually weld, melt or
voltage difference between the two areas badly pit the rope.
could kill (see figure 8.2)
Proximity warning devices, insulating
• inform the electricity distribution boom guards and similar devices all have
authority of the situation immediately. limitations and should not be relied upon
Until assistance arrives, someone to give protection against electric shock.
should remain near the crane, but at a
safe distance, to warn others of the
danger of approaching
51
Part 8: Erection cont.
If a suspended slab is used to support the Sling lengths are critical where the rigging
crane, the slab should be designed for the system includes the use of spreader
crane point loads. A suitable propping beams or lifting beams with slings running
system may be required and, if so, should through sheaves. The rigging system
be designed in accordance with the should be designed to suit the spacing and
requirements of the appropriate Australian layout of the lifting inserts.
Standards. Single, double and four-leg slings are
commonly used in the handling of precast
8.9 Rigging
elements. In selecting the sling capacity,
Setting up a rigging system requires the increased force due to inclination of
careful and thorough pre-planning. The the sling and the change of direction at
selection of the rigging system connecting reeving points should be considered. The
the precast or tilt-up element to the crane included angle between slings at reeving
should be agreed between the precaster points should not exceed 120 degrees.
and erector. The selected configuration
When lifting precast elements with fixed
must be specified in the shop drawings
length multi-legged slings, any two legs of
and must not be altered without the
the slings must be capable of supporting
approval of the precaster or the erection 53
the total load.
design engineer.
Part 8: Erection cont.
The rigging system should be arranged to Where precast elements need to be rotated
allow the precast element to lie in or near by use of a tailing lifter (lifting insert at the
its correct attitude for erection into the bottom of the element), the required
structure. This can be accomplished capacity of the crane winch being used to
through one or more of the following rotate the element must be determined.
means:
Up to 70% of the mass of the element can
• appropriate location of the lifting inserts be taken by the tail lifter during rotation.
• use of a lifting beam with offset lifting This is particularly critical for edge-lifted
points wall panels (see figure 8.3).
• correct location of the slinging point or General rigging practices not dealt with
points in the element specifically in this Industry Standard
• use of a counterweight should be consistent with the advice
provided in WorkCover’s A Guide to
Where possible, three rows of inserts
Rigging.
should be avoided due to the complex
rigging configurations required. Preferred
configurations are shown in figure 4.1.
Tailing lifter
or lifters
54
Part 8: Erection cont.
56
Part 8: Erection cont.
57
Part 8: Erection cont.
Wall panel
150mm MIN
58
Part 8: Erection cont.
59
Part 8: Erection cont.
Braces must be marked as set out in For face-lifted wall panels, bracing inserts
section 4.11. should be on the same face of the panel as
the lifting inserts.
Brace adjustment mechanisms must have
stops on the threads to prevent over- When, under unusual circumstances, it is
extension and retaining devices to prevent necessary to attach the braces after a wall
unintentional dislodgment of the shear panel has been positioned, the wall panel
pins. The shear pins should be should be held firmly, safely and just past
constructed so that they cannot be undone vertical by the crane while the braces are
without the use of a tool. installed.
Whenever possible, the braces should be Until it is secured, no one should ever
fixed to the precast or tilt-up concrete work on a panel that is leaning towards
element before lifting. them.
Bracing insert capacities are sensitive to: Generally, a minimum of two braces
• the method of installation should be used for all tilt-up and precast
elements.
• the strength of the concrete into which
they are placed Two braces may not be necessary where
• the distance from the insert to the edge elements are provided with erection
of the element brackets or permanent connections to
other restrained elements such as steel
Unless specified otherwise in the shop
portal columns or precast walls forming a
drawings, bracing inserts must not be
stable “box” structure.
closer than 300 mm to the edge of the
element, footing or other bracing support. If expansion anchors are to be used as
bracing inserts in the floor or brace
During the lifting process, the braces
footings, the type and their capacity
should not hang below the base level of
should be assessed in accordance with
the element. This may be achieved by the
part 4 and should be clearly specified on
use of adjustable brace lengths or by the
the shop drawings.
use of taglines (tail ropes).
60
Part 8: Erection cont.
61
Part 8: Erection cont.
Where beams are to have floor systems beam during construction. With floor units
placed on them prior to the beams being placed only on one side of a beam,
fully built into the structure, allowance additional temporary propping may be
should be made for uneven loading on the required to each edge of the beam (see
figure 8.5).
OVERTURNING TORQUE
Precast floor unit
Precast beam
Column top or
column bracket
62
Part 8: Erection cont.
Where required, all temporary propping The shop drawings should clearly specify
should be in place and fully braced prior to the required propping forces and show
commencement of erection of any precast details of the fixing to the precast element
elements. and the prop footing.
63
Part 8: Erection cont.
64
Part 9:
Proprietary elements
9.1 Application Design computations must be prepared by
a suitably experienced engineer and
This part relates to precast elements that
certified by a registered building
are manufactured by a mechanical process
practitioner in accordance with the
in a factory environment. Such proprietary
requirements of the Building Act 1993.
elements are frequently based on specific
design processes that are only available to Design computations or suitable
the precaster and where the component is certification for the proprietary elements
usually supplied on a design and must be submitted to the project design
manufacture basis. engineer for review and for verification of
compliance with the overall design
Examples of proprietary elements include:
requirements.
• hollowcore floor slabs
• transfloor slabs and beams 9.3 Design for erection
• ultrafloor beams and infills The design for erection should comply
Proprietary elements are deemed-to- with the requirements of part 4, including
satisfy the overall requirements of this the section on special provisions.
Industry Standard if they comply with the Shop drawings must be prepared and
following clauses and with the intent of the issued to the builder for approval and
remaining parts of this Industry Standard. review by the building designer and project
design engineer.
9.2 General design provisions
Where the precaster is responsible for the 9.4 Manufacture
design of the elements, the precaster must Elements must be manufactured in
ensure that the design complies with all accordance with a work method statement
the requirements specified by the project provided by the precaster. The work
design engineer. method statement should comply with the
The design must be in accordance with the general requirements of this Industry
relevant Australian Standards or, where Standard and specifically address the
not specifically covered by Australian issues relating to the manufacturing
Standards, the relevant sections of US or process of the elements in question.
European standards. 65
Part 9: Proprietary elements cont.
66
Part 9: Proprietary elements cont.
67
68
Appendix A: Referenced
documents and further reading
Acts referenced Australian Standards referenced
• Building Act 1993 • AS 1170.2, Minimum Design Loads on
Structures, part 2: Wind Loads
• Occupational Health and Safety Act
1985 • AS 1311, Steel Tendons for Prestressed
Concrete – 7-wire Stress-relieved Steel
WorkCover publications Strand Tendons in Prestressed
referenced Concrete
• A Guide to Rigging • AS 1379, Specification and Supply of
• Code of Practice for Building and Concrete
Construction Workplaces • AS 2550, Cranes – Safe Use
• Code of Practice for First Aid in the • AS 3600, Concrete Structures
Workplace • AS 3610, Formwork for Concrete
• Guidance Note for Amenities on • AS 3850, Tilt-up Concrete
Housing Construction (Cottage Construction*
Industry) Sites
Note: *This Standard has undergone
• Guidance Note for Use of Anchors as review and revision. It is expected to be
Bracing Inserts in Precast Concrete published in its revised format during
Panels 2001.
• WorkCover Incident Notification
69
Appendix A: Referenced documents and further reading cont.
71
Appendix B: Definitions of terms
used in this Industry Standard
B1: General definitions practitioner and be competent to practice
in the structural engineering field. The
builder erection design engineer will usually be
The company or person responsible for responsible to the builder, the precaster or
the construction of the completed building the shop detailer, or may also be the
and who has control of the building site. project design engineer.
The builder may also be the client or a
company or person responsible to the precaster
client. The company or person responsible for
manufacturing the precast or tilt-up
building designer concrete elements. The precaster will
The project architect or project designer usually be sub-contracting to, and be
responsible for the design of the building. responsible to, the builder. The precaster
The building designer will usually be may sometimes be referred to as the
responsible to the client. precast concrete manufacturer or tilt-up
manufacturer.
client
The owner of the building or the company precast concrete element
or person responsible for developing the A concrete element manufactured under
building. controlled conditions in a factory or
casting yard and subsequently transported
erector
to and erected on a building site.
The company or person responsible for
erecting the precast or tilt-up concrete project design engineer
elements. The erector may be responsible The consulting engineer responsible for
either to the builder, precaster, or client. the engineering design of the building. The
project design engineer should be a
erection design engineer
person qualified for membership of the
The engineer responsible for the design for Institution of Engineers Australia, be a
the erection of the precast elements of the registered building practitioner and be
building. The erection design engineer competent to practice in the structural
should be a person qualified for engineering field. The project design
72 membership of the Institution of Engineers engineer will usually be responsible to the
Australia, be a registered building client.
Appendix B: Definitions of terms used in this Industry Standard cont.
73
Appendix B: Definitions of terms used in this Industry Standard cont.
___________________________________________________________________________
This is to certify that the erection design and detailing for the above project as carried out by
this firm is in accordance with:
• AS 3600 and/or AS 3850 (as appropriate), and
• The Victorian Industry Standard Precast and Tilt-up Concrete for Buildings
Name ___________________________________________________________________
Signature ________________________________________________________________
Date ____________________________________________________________________
The person completing and signing this certificate must be an engineer, a person qualified
for corporate membership of the Institution of Engineers Australia (or equivalent), a
registered building practitioner and be competent to practise in the design of precast
concrete.
76
Appendix D: Manufacturer’s
certificate of compliance
Precast and tilt-up concrete elements
Project __________________________________________________________________
Precaster/manufacturer _____________________________________________________
Builder __________________________________________________________________
Schedule of elements
Identification Casting Identification Casting
number date number date
___________________________________ ___________________________________
___________________________________ ___________________________________
___________________________________ ___________________________________
___________________________________ ___________________________________
___________________________________ ___________________________________
___________________________________ ___________________________________
___________________________________ ___________________________________
___________________________________ ___________________________________
This is to certify that the abovelisted precast or tilt-up concrete elements have been
manufactured in accordance with the approved shop drawings.
Name ______________________________________________________________________
Signature ___________________________________________________________________
Date _______________________________________________________________________ 77
78