Precast Concrete Handling

Every precast element has a fixed attachment point, a surface that can't be marked, and a weight distribution that isn't always obvious. The lift has to be right before the element leaves the casting yard.

Precast concrete combines brutal dead weight with geometry that doesn't always cooperate. Panels, stairs, beams, columns, and hollowcore units each lift differently - and the anchor inserts are cast in at manufacture, so there's no adjusting your pick points on site. If the specified lifting arrangement doesn't match the actual centre of gravity, you find out when the load angles on the way up. At that point, the options are limited and the risks are significant.

Precast Concrete Challenges

Fixed attachment points with no adjustment

Unlike steel, where you can move a beam clamp along the flange, precast lifting inserts are cast in during manufacture. Their positions are determined by the element design - and they may or may not perfectly account for the actual centre of gravity of a non-standard piece. Before any lift, the insert positions, the element weight, and the intended lifting arrangement need to be verified against each other. Discovering a mismatch after the crane is hooked up is not the time to improvise.

Centre of gravity varies by element type

A flat wall panel and an L-shaped stair flight are both precast concrete, but they lift completely differently. Hollowcore planks, double-T units, and architectural cladding panels each have their own CoG characteristics. Specifying the same lifting arrangement across different element types without checking the geometry is a shortcut that causes incidents. Each element type needs its own assessed lifting configuration.

Surface-critical finishes that can't be marked

Architectural precast - fair-faced concrete, exposed aggregate, polished finishes - has zero tolerance for contact marks, abrasion, or pressure damage from rigging. Textile round slings are the standard choice here; wire rope or chain in direct contact with a finish-critical surface is not acceptable. Where elements must be turned or tilted during installation, the rigging arrangement needs to protect the finish throughout the entire manoeuvre, not just during the main lift.

Rotation and tilt during installation

Many precast elements are cast horizontal and installed vertical - wall panels being the most common example. That means the lift includes a controlled rotation before final placement, which puts different loads through the inserts and the slings at different points in the operation. The lifting arrangement has to be designed for the full sequence, not just the end position. Swivel hoist rings and purpose-designed tilting frames exist precisely for this reason.

What the regulations require

Precast lifting is tightly governed - both by general lifting legislation and by the specific requirements around cast-in lifting anchors and the elements themselves.

Key standards and guidance for precast concrete handling:

■ LOLER 1998: all lifting equipment must be thoroughly examined at the required intervals; a written lift plan is required for complex or non-routine lifts

■ EN 13155: the standard governing non-fixed load lifting attachments; lifting clutches and anchors used with precast elements must meet this standard

■ Manufacturer WLL ratings: cast-in inserts have load ratings defined by the insert manufacturer for specific anchor types, embedment depths, and concrete strengths. These ratings are not interchangeable between manufacturers or insert types

■ BS 8666: scheduling and detailing of reinforcement; relevant where insert positioning interacts with the rebar layout

■ CDM 2015: precast installation is a significant structural operation; lifting sequences should be addressed in the construction phase plan and pre-construction information should include element weights and insert specifications

The element manufacturer should provide a lifting specification for each element type. If that documentation is missing or incomplete, do not assume the lift is straightforward.

Lifting & Spreader Beams

Lifting a precast element type you haven't handled before?

Tell us about the element, the inserts, and the installation sequence and we'll make sure the lifting arrangement is right before you're on site. Precast lifts are not the place to work it out as you go.

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