CON/Specific/TBT-CON-012

Precast Element Handling

Concrete & Formwork › Specific › Precast Element Handling

Presenter		Project
Location		Date

Precast concrete elements include beams, columns, slabs, walls, stairs, and cladding panels.
Weights range from a few hundred kilograms for lintels to over 20 tonnes for bridge beams.
Every precast element must be lifted using the cast-in lifting points specified by the manufacturer.
A lift plan compliant with LOLER 1998 is required for every precast element being lifted.
Elements are vulnerable to cracking and damage during transport, storage, and handling on site.
Temporary propping and bracing must be installed immediately after placing to prevent collapse.
Workers must never stand under a suspended precast element during lifting and positioning.
Storage on site must use level ground, correct dunnage spacing, and stable stacking arrangements.
Connections between precast elements must be completed before temporary supports are removed.
Wind loading on large flat panels during lifting can cause sudden uncontrolled swinging.

Crush fatalities	Dropped precast elements and collapses during placement have caused multiple worker deaths on UK construction sites.
Structural integrity	Incorrect handling damages precast elements, creating hidden cracks that compromise structural performance once installed.
Legal compliance	LOLER 1998 and CDM 2015 require planned, supervised lifting with competent people for all precast operations.

Don't

Lift precast elements only from the cast-in lifting points specified by the manufacturer.
Prepare a LOLER-compliant lift plan for every precast element before lifting.
Install temporary propping and bracing immediately after placing each element.
Store precast elements on level ground with correct dunnage and stable stacking.
Establish exclusion zones beneath all precast lifting and placement operations.
Check elements for transport damage before lifting them into position.
Complete permanent connections before removing any temporary support or propping.
Monitor wind conditions and stop lifting large panels in high winds.
Brief the lifting team on the sequence, signals, and emergency procedures.
Use tag lines to control elements during lifting and prevent swinging.

DON'T lift precast elements from points other than the designated lifting inserts.
DON'T stand under a suspended precast element at any time during the lift.
DON'T remove temporary propping before permanent connections are fully complete.
DON'T stack precast elements higher than the manufacturer's storage recommendations.
DON'T lift large flat panels in wind conditions that cause uncontrolled movement.
DON'T use damaged or corroded lifting inserts without engineering assessment.
DON'T proceed with a lift if the element weight exceeds the crane's chart capacity.
DON'T release the crane hook until the element is confirmed stable and propped.
DON'T store elements on uneven ground or without proper dunnage support.
DON'T skip the pre-lift briefing; every team member must know their role.

See also: Lifting Precast Concrete Elements | Lifting Operations Awareness (LOLER)

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