Safe Work Method Statement

Tilt-up Panel Lifting Safe Work Method Statement

Comprehensive Australian WHS Compliant SWMS

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Tilt-up panel lifting and erection represents one of the highest-risk operations in construction, involving the use of mobile cranes to raise multi-tonne concrete wall panels from horizontal casting position to vertical erected position. This process requires precise coordination between crane operators, dogmen, bracing crews, and site supervisors, with panel weights typically ranging from 15 to 60 tonnes and heights extending up to 12 metres. Workers face catastrophic hazards including panel collapse during lifting or bracing, crane overload or tipping, struck-by falling panels or bracing components, crushing injuries in exclusion zones, and wind-induced instability of partially braced panels. This Safe Work Method Statement implements controls mandated by the National Code of Practice for Precast, Tilt-up and Concrete Elements in Building Construction and Australian Standards for crane operations.

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Overview

What this SWMS covers

Tilt-up panel erection involves rotating cast concrete panels from horizontal position on floor slabs to vertical erected position forming building walls. The process begins with engineered lifting design determining crane capacity requirements, rigging configurations, lift point locations, and bracing systems. Mobile cranes position adjacent to panels with outriggers deployed on stable ground providing adequate capacity for panel weight plus dynamic loads during lifting. Specialized panel lifting equipment including vacuum lifters or bolt-on rigging systems connect cranes to embedded lifting inserts in panels. The lifting sequence progresses systematically around building perimeter with panels erected in planned order allowing bracing installation and structural connections. Each panel lift involves initial pick breaking panel free from floor slab release bond, controlled rotation from horizontal toward vertical through critical angle where panel center of gravity shifts, positioning panel at designated location guided by surveyed floor marks, and final verticality adjustment before temporary bracing installation. Ground personnel guide panel positioning using tag lines while maintaining safe distances from potential crush zones. Temporary bracing systems must support panels against all applied loads including wind, seismic, and construction loads until permanent connections and roof structure provide stability. Bracing typically consists of steel pipe or timber props extending from panel face to ground anchors or slab connections, with minimum two braces per panel oriented perpendicular to panel plane. Panel stability is critically dependent on proper bracing installation, with premature brace removal causing catastrophic panel collapse. All bracing remains in place until structural engineer certifies permanent stability has been achieved through completed roof framing and permanent panel connections. Weather conditions significantly impact lifting operations, with wind being primary constraint. Australian standards limit panel erection when wind speeds exceed 10 metres per second (36 km/h) at panel height due to large panel surface areas acting as sails creating uncontrollable lateral forces. Real-time wind monitoring using anemometers positioned at panel height provides objective decision-making criteria. Lifting operations suspend immediately if wind thresholds approach during panel lifts, with panels lowered to ground rather than risking mid-lift instability.

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Why this SWMS matters

Panel collapse during or after lifting causes fatalities and catastrophic injuries in Australian construction with distressing regularity. Safe Work Australia investigation reports identify common causation factors including inadequate temporary bracing, premature brace removal, insufficient crane capacity, wind loads exceeding design assumptions, and coordination failures between crane operators and ground crews. A single panel collapse can cause multiple fatalities when panels weighing 30-60 tonnes fall across work areas crushing personnel unable to escape impact zones. The public risk extends beyond workers, with panels collapsing onto adjacent roads, buildings, or public areas creating community safety hazards. Crane overload and tipping during panel lifts occurs when actual panel weight exceeds estimated weight used for crane selection, when dynamic forces during rotation exceed capacity margins, or when ground subsidence under outriggers reduces stability. Mobile cranes operating at capacity limits have minimal safety margins, with slight overload causing tipping or structural failures. The confined site areas typical of tilt-up construction often require cranes to work at extended radii or over-side configurations reducing available capacity. Load monitoring systems and accurate panel weight calculations are essential for preventing crane failures. Struck-by hazards from panels under crane control create large exclusion zones where personnel must not enter. During lifting and positioning, panels can swing unexpectedly from wind gusts, crane movements, or tag line forces. Ground personnel positioned too close to panels can be struck by moving panels or crushed between panels and structures. The noise from diesel cranes and activity on construction sites prevents verbal warnings being heard, requiring visual communication systems and physical barriers enforcing exclusion zones. The National Code of Practice for Precast, Tilt-up and Concrete Elements mandates that tilt-up panel erection must not commence until comprehensive engineering design is completed covering crane selection, rigging systems, temporary bracing, and panel stability. This design must be prepared by qualified structural engineers and reviewed before any lifting operations. The code further requires documented procedures, competent personnel holding appropriate high-risk work licenses, and strict weather monitoring protocols. Recent prosecutions following panel collapse incidents have resulted in fines exceeding $2 million, with courts finding that inadequate engineering design and failure to follow documented procedures directly caused fatalities.

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Hazard identification

Surface the critical risks tied to this work scope and communicate them to every worker.

Risk register

Catastrophic Panel Collapse During or After Erection

high

Tilt-up panels are inherently unstable in vertical position until permanent structural connections are completed, relying entirely on temporary bracing for stability. Panel collapse occurs from inadequate bracing design, incorrect bracing installation, premature brace removal, excessive wind loads exceeding bracing capacity, ground anchor failure, or panel impact during adjacent panel erection. Panels weighing 30-60 tonnes falling from vertical position create impact zones extending 1.5 times panel height from base. Personnel working near erected panels, installing bracing, or performing subsequent construction activities face crushing hazard from falling panels. Multiple fatalities can occur from single panel collapse when panels fall across work areas or create domino collapse of adjacent panels. The sudden collapse provides no warning allowing escape, with death often instantaneous from crushing forces.

Consequence: Fatal crushing injuries to multiple workers from panel collapse impact, catastrophic traumatic injuries including severe fractures and internal damage to survivors, property damage extending to adjacent buildings and vehicles, project delays extending months while investigations complete and rebuild occurs, massive financial liability from WorkCover claims and prosecution penalties, and permanent loss of business reputation.

Mobile Crane Tipping or Structural Failure During Lifts

high

Mobile cranes operating near capacity limits during heavy panel lifts can tip if loads exceed capacity charts, ground beneath outriggers subsides, or wind creates lateral loads. Crane structural failures including boom collapse occur from metal fatigue, inadequate maintenance, or overload conditions. The combination of panel weight (often 20-40 tonnes), extended radius reaching from crane position to panel location, and dynamic forces during panel rotation creates demanding load conditions. Inaccurate panel weight estimates due to reinforcement steel, embedded fixtures, or concrete density variations cause unexpected overloads. Ground conditions on construction sites may not provide adequate bearing capacity for outrigger loads which can exceed 100 tonnes per outrigger for large panel lifts.

Consequence: Fatal injuries to crane operators and ground personnel from crane tipping or boom collapse, severe traumatic injuries including crushing and impact trauma, destruction of expensive crane equipment requiring replacement, catastrophic property damage from falling cranes impacting buildings or vehicles, extended project delays while replacement cranes are sourced, and potential WorkCover prohibition notices stopping all crane operations on site.

Struck-by Suspended or Moving Panels During Positioning

high

Panels under crane control can swing unexpectedly creating struck-by hazards for ground personnel. Wind gusts act on panel surfaces creating lateral forces swinging panels despite crane controls. Tag line forces applied to guide panel positioning can cause sudden panel movements if lines slip or release unexpectedly. Crane operator movements including boom slewing or trolley travel create intended panel travel that may not be visible to ground personnel. The confined work areas around building perimeters position workers near suspended panels without adequate clearance. Communication difficulties between crane operators and ground personnel due to noise, visual obstructions, or radio failures result in uncoordinated movements. Personnel positioning themselves between panels and structures to install bracing or permanent connections face crushing hazard if panels move toward structures.

Consequence: Fatal crushing injuries from being struck by or pinned between suspended panels and structures, severe traumatic injuries including amputations from being caught between panels and building elements, head and spinal injuries from panel impact, psychological trauma for workers witnessing struck-by incidents, and WorkCover prosecution for inadequate exclusion zone enforcement.

Wind-Induced Panel Instability During and After Erection

high

Large tilt-up panels present substantial surface areas acting as sails subjected to wind forces. Panels typically 8-12 metres high and 3-10 metres wide create wind loads that can exceed bracing capacity in moderate wind conditions. During lifting, panels rotate through various angles changing wind loading characteristics, with maximum wind loads occurring when panels are 30-60 degrees from vertical. Once erected, panels remain vulnerable to wind until permanent roof structure provides restraint, typically requiring 2-4 weeks. Wind gusts create dynamic loads exceeding steady-state wind forces, with peak loads potentially double average wind speeds. The bracing systems are designed for specific wind speeds (typically 36 km/h maximum), with higher winds causing brace failure and panel collapse. Forecasted wind conditions may not reflect actual site conditions due to local geography, adjacent buildings creating turbulence, or rapidly changing weather patterns.

Consequence: Panel collapse from wind loads exceeding bracing capacity causing fatal crushing injuries, domino collapse of multiple panels if initial collapse impacts adjacent panels, crane instability if wind acts on suspended panels during lifts forcing emergency load lowering, property damage to adjacent structures from falling panels, and project delays while collapsed panels are replaced and stability reassessed.

Inadequate Ground Conditions Causing Crane or Brace Anchor Failure

medium

Mobile crane outriggers and temporary bracing ground anchors require firm, stable ground providing adequate bearing capacity for imposed loads. Construction sites often have disturbed ground from excavation, services installation, or previous structure demolition creating variable ground conditions. Outrigger loads from large cranes can exceed 100 tonnes per pad, with inadequate bearing capacity causing ground subsidence during lifts resulting in crane instability. Temporary brace ground anchors must resist both compression and uplift forces as wind loads vary, with anchor failure causing immediate loss of panel restraint. Underground voids from abandoned services, poorly compacted fill, or soft soils reduce bearing capacity without visible surface indication. Groundwater infiltration or rain saturation further reduces bearing strength.

Consequence: Crane tipping from outrigger subsidence causing operator fatality and equipment destruction, panel collapse from brace anchor failure causing worker crushing injuries, inability to complete lifts safely resulting in project delays, expensive ground improvement requirements including piling or ground stabilization, and need for engineering reassessment of all subsequent lifts.

Control measures

Deploy layered controls aligned to the hierarchy of hazard management.

Implementation guide

Engineered Lifting and Bracing Design by Qualified Structural Engineer

Elimination

Mandate comprehensive engineering design before any panel lifting operations, with qualified structural engineers determining crane requirements, rigging configurations, lift point locations, temporary bracing systems, ground bearing requirements, and wind limitations. This engineering design eliminates ad-hoc decision-making and establishes objectively safe parameters for all lifting activities.

Implementation

1. Engage structural engineer registered in Queensland/relevant state with demonstrated tilt-up design experience 2. Provide engineer with accurate panel dimensions, weights including reinforcement and embedded items, and concrete strength data 3. Require engineer to specify crane minimum capacity including dynamic load factors and safety margins 4. Design lifting insert locations, embedment depths, and rigging systems including spreader bars or vacuum lifters 5. Engineer designs temporary bracing systems specifying brace sizes, quantities, orientations, and ground anchor requirements 6. Calculate wind load limits for lifting operations and specify maximum wind speeds for safe erection 7. Require engineer certification that panels meet minimum strength (typically 75% of 28-day strength) before lifting 8. Document ground bearing capacity requirements for crane outriggers and brace anchors with testing if required 9. Design permanent connections providing panel stability and specify construction sequence allowing brace removal 10. Engineer provides written certification that all designs comply with relevant Australian Standards before lifting commences

Exclusion Zones and Physical Barriers During Panel Lifts

Engineering Control

Establish physical exclusion zones preventing personnel from entering potential panel fall or swing zones during lifting operations. Exclusion zones extend 1.5 times panel height from panel base in all directions, physically marked with barriers that cannot be crossed inadvertently.

Implementation

1. Calculate exclusion zone radius as 1.5 times maximum panel height for site being erected 2. Mark exclusion zones using barrier fencing or tape creating physical boundary visible from all approaches 3. Install warning signs at exclusion zone boundaries stating 'DANGER - Panel Lifting in Progress - No Entry' 4. Position barriers before crane arrives preventing access during setup and throughout lifting operations 5. Assign dedicated safety officer monitoring exclusion zones and preventing unauthorized entry 6. Brief all site personnel at pre-lift meeting covering exclusion zones and entry prohibition 7. Prohibit personnel from entering exclusion zones even momentarily during suspended loads 8. Allow only essential personnel including crane operator, dogman, and bracing crew in adjacent areas 9. Maintain exclusion zones until panels are fully braced, inspected, and certified stable by engineer 10. Document exclusion zone compliance in daily lift logs noting any breaches and corrective actions

Real-Time Wind Monitoring with Defined Suspension Criteria

Administrative Control

Implement continuous wind monitoring during panel lifting operations using calibrated anemometers positioned at panel height, with documented suspension criteria requiring immediate lift cessation when wind speeds approach design limits. This provides objective decision-making removing reliance on subjective wind assessment.

Implementation

1. Install anemometer on temporary mast or building element at height matching erected panel tops 2. Position wind monitoring display visible to crane operator and lift supervisor providing real-time data 3. Establish wind speed limits typically 10 m/s (36 km/h) sustained or 12 m/s gusts for standard panels 4. Conduct pre-lift wind assessment checking forecast and current conditions before commencing operations 5. Monitor wind continuously throughout lifting operations with designated person watching display 6. Implement immediate suspension protocol if winds exceed 80% of design limit, lowering any suspended panels 7. Prohibit lifting operations when forecast predicts wind speeds approaching limits during planned lift window 8. Document wind conditions at time of each panel lift recording maximum sustained and gust speeds 9. Require wind speeds to remain below limits for minimum 15 minutes before resuming suspended operations 10. Calibrate anemometer monthly verifying accuracy and maintaining calibration certificates

Crane Capacity Verification and Load Monitoring

Engineering Control

Verify crane selection provides adequate capacity for heaviest panels at required radius with safety margins accounting for dynamic loads and wind forces. Implement load monitoring during lifts detecting overload conditions before crane stability is compromised.

Implementation

1. Calculate actual panel weights including concrete volume, reinforcement steel, and embedded fixtures rather than using estimates 2. Add 20% dynamic load factor to static panel weight accounting for acceleration forces during rotation 3. Verify crane capacity chart provides minimum 1.25 safety factor at required radius and configuration 4. Inspect crane compliance certification, current inspection tags, and maintenance records before operations 5. Test crane load moment indicator (LMI) functionality before first lift verifying alarms activate at rated capacity 6. Monitor LMI readout during all lifts maintaining loads at 80% or less of rated capacity 7. Implement three-point outrigger leveling verification ensuring all outriggers equally loaded and pads on firm ground 8. Use outrigger mats or crib packs increasing bearing area on soft ground conditions 9. Prohibit crane repositioning with suspended loads or over-hoisting beyond boom angle limits 10. Document crane configurations, actual lifted weights, and LMI readings for all panel lifts in daily log

Documented Bracing Installation and Inspection Procedures

Administrative Control

Implement systematic bracing installation procedures following engineered design with documented inspections verifying correct installation before crane releases panels. This prevents inadequate bracing creating immediate collapse risk when crane loads are transferred.

Implementation

1. Fabricate bracing components off-site to specified dimensions eliminating field modifications 2. Mark brace locations on floor slab using surveyed positions from engineering drawings 3. Install ground anchors to specified embedment depths and orientations before panel erection 4. Position braces immediately after panel reaches vertical with minimum two braces before crane release 5. Install brace connections to panel and ground anchors using specified fasteners torqued to engineer requirements 6. Adjust braces using turnbuckles or adjustment mechanisms achieving panel plumb within 1:200 tolerance 7. Verify brace angles match engineering design typically 45-60 degrees from horizontal 8. Inspect all brace connections checking secure fastening and no damaged components before crane releases 9. Require structural engineer or delegated competent person to certify adequate bracing before crane disconnection 10. Prohibit brace removal until engineer certifies permanent connections provide stability, typically after roof framing complete

Communication Systems and Coordination Procedures

Administrative Control

Establish clear communication protocols between crane operator, dogman, bracing crew, and lift supervisor using radio systems and visual signals. Effective communication prevents coordination failures causing uncontrolled panel movements or premature crane releases.

Implementation

1. Provide two-way radios for crane operator, dogman, and lift supervisor on dedicated channel 2. Test radio communication before each lifting session verifying clear transmission and reception 3. Designate single dogman responsible for all crane communications using standardized hand signals 4. Prohibit any person other than designated dogman from directing crane operator during panel lifts 5. Establish clear verbal protocols including 'stop', 'lower', 'hold' commands understood by all participants 6. Brief crew at pre-lift meeting covering communication protocols, emergency signals, and individual responsibilities 7. Implement confirmation system where crane operator repeats commands before acting 8. Establish signal for emergency stop requiring immediate cessation of all crane movements 9. Maintain continuous communication throughout lift with dogman providing running commentary on panel position 10. Document communication protocols in lift plan with emergency contact numbers for supervisor and engineer

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Personal protective equipment

Hard Hat Class B with Chin Strap

Requirement: Type 1 per AS/NZS 1801 with secure chin strap preventing dislodgement

When: Required for all personnel in panel lifting areas due to extreme overhead hazards from suspended panels

Steel Cap Safety Boots

Requirement: 200 joule impact rating per AS/NZS 2210.3

When: Mandatory for all site personnel due to heavy materials and crushing hazards from panels and bracing

High-Visibility Clothing Class D Day/Night

Requirement: Fluorescent background with reflective tape per AS/NZS 4602.1

When: Required for all personnel ensuring visibility to crane operators and mobile plant drivers

Safety Glasses with Side Shields

Requirement: Medium impact rated per AS/NZS 1337

When: Required during all panel lifting operations protecting from flying debris and dust

Safety Harness with Double Lanyard

Requirement: Full-body harness per AS/NZS 1891.1 with shock-absorbing lanyards

When: Required for workers installing bracing at heights exceeding 2 metres or on elevated work platforms

Cut-Resistant Gloves

Requirement: Level 3 per AS/NZS 2161.4 when handling rigging and steel components

When: Required when handling wire ropes, chains, and steel bracing components with sharp edges

Inspections & checks

Before work starts

✓Verify engineering design documentation complete including lift plan, bracing design, and crane capacity calculations
✓Inspect crane for current registration, third-party inspection certification, and operator licensing documentation
✓Check concrete strength cylinders confirm panels meet minimum 75% of 28-day strength before lifting authorized
✓Test crane load moment indicator (LMI) functionality and verify safety systems including outrigger interlocks operational
✓Inspect ground conditions under crane outriggers and brace anchor locations for adequate bearing capacity
✓Verify wind monitoring equipment installed and functional with display visible to operators
✓Check lifting inserts in panels are clean, undamaged, and correctly oriented for rigging connections
✓Confirm exclusion zones marked with physical barriers and warning signage at all access points
✓Test radio communication systems between crane operator, dogman, and supervisor ensuring clear transmission
✓Verify all personnel have completed site induction and understand emergency procedures including evacuation routes

During work

✓Monitor wind speed continuously suspending lifts immediately if approaching 10 m/s sustained or 12 m/s gusts
✓Observe crane load moment indicator maintaining loads at 80% or less of rated capacity throughout lifts
✓Check exclusion zones remain clear of all non-essential personnel during panel suspension and positioning
✓Verify outrigger stability watching for ground subsidence or pad movement indicating inadequate bearing capacity
✓Inspect rigging connections to panels before lifting confirming secure attachment and load distribution
✓Monitor panel rotation watching for unexpected swinging or unstable behavior requiring immediate lowering
✓Check bracing installation ensuring minimum two braces installed and secured before crane releases panel
✓Verify panel vertical alignment using levels confirming plumb within 1:200 tolerance before final bracing
✓Observe communication effectiveness between dogman and crane operator intervening if commands unclear or missed
✓Inspect completed panels for any cracking, movement, or instability requiring immediate engineering assessment

After work

✓Verify all panels adequately braced with engineer certification of stability before crane demobilizes
✓Inspect brace connections confirming all fasteners secure and no damaged components requiring replacement
✓Check panel alignment and plumb measurements documenting any panels outside tolerance for remediation
✓Document all panel lifts including weights, wind conditions, crane configurations, and any issues encountered
✓Photograph erected panels showing bracing installation and panel positions for quality assurance records
✓Mark completed panels indicating bracing installation dates and prohibiting brace removal without engineer authorization
✓Clean work areas removing rigging equipment, excess materials, and trip hazards from panel erection activities
✓Maintain exclusion zones around erected panels until permanent connections installed providing stability
✓Inspect crane for any damage during operations documenting findings and required maintenance before next shift
✓Debrief crew on lifting operations identifying any near-misses or improvement opportunities for remaining panels

Step-by-step work procedure

Give supervisors and crews a clear, auditable sequence for the task.

Field ready

Pre-Lift Engineering Review and Site Preparation

Conduct comprehensive review of engineering documentation before commencing any lifting operations. Verify structural engineer has certified panel concrete strength meets minimum requirements (typically 75% of 28-day strength) through cylinder testing. Review crane selection calculations confirming chosen crane provides adequate capacity for heaviest panels at required working radius with safety margins. Examine lifting insert locations, rigging design, and temporary bracing specifications. Inspect ground conditions where crane outriggers and brace anchors will be positioned, conducting bearing capacity testing if ground conditions questionable. Install ground anchors for temporary bracing at surveyed locations matching engineering drawings. Mark panel erection sequence on floor slab identifying lift order and final panel positions. Establish exclusion zones using barrier fencing positioned 1.5 times maximum panel height from panel bases. Install wind monitoring equipment at panel height locations. Conduct pre-lift meeting with all personnel covering lift plan, communication protocols, individual responsibilities, emergency procedures, and wind suspension criteria.

Safety considerations

Ensure all workers understand and acknowledge their specific roles before operations commence. Verify emergency contact information including structural engineer and emergency services readily available. Confirm first aid and rescue equipment accessible.

Crane Setup and Pre-Operational Checks

Position mobile crane on firm, level ground at location providing reach to all panels being lifted without repositioning during panel lifts. Deploy outriggers to maximum extension ensuring all four outriggers fully extended and locked. Install outrigger pads beneath outrigger feet increasing bearing area on soft ground, using timber mats or steel plates as required by ground conditions. Level crane chassis using outrigger adjustments achieving bubble level indication on crane platform. Test crane functions including boom raise/lower, slew, and hoist systems verifying smooth operation and no unusual noises. Verify load moment indicator (LMI) functioning by approaching rated capacity with test load, confirming alarm activation. Inspect wire ropes, sheaves, and hook blocks checking for wear, damage, or lubrication needs. Verify crane operator holds current high-risk work license (C2 or CN rating appropriate for crane capacity). Review crane capacity chart at planned configuration and radius confirming adequate capacity for panels being lifted. Establish communication system with crane operator receiving two-way radio and testing transmission quality.

Safety considerations

Never position crane over underground services or within minimum clearance distances from overhead power lines. Ensure ground beneath outriggers provides adequate bearing capacity verified by engineer if questionable. Monitor outriggers throughout operations for any subsidence indicating ground failure.

Panel Rigging and Initial Lift

Clean lifting inserts in panel tops removing any concrete, dirt, or debris preventing secure rigging connections. Install lifting equipment as designed by engineer, typically vacuum lifters for architectural panels or bolt-in rigging for structural panels. Verify lifting points align with crane hook position when rigging is under load. If using spreader bars, check bar dimensions match design and all rigging connections are secure. Attach crane hook to lifting equipment with dogman conducting final inspection of all connections. Establish clear communication between dogman and crane operator using standardized hand signals or radio commands. Begin initial lift slowly taking slack from rigging and lifting panel just enough to tension rigging allowing visual inspection. Inspect all rigging connections under load confirming secure attachment and even load distribution. If connections appear uneven or any rigging component shows distress, lower panel immediately and adjust rigging before proceeding. Once rigging confirmed adequate, continue lift breaking panel free from floor slab bond. Monitor load moment indicator confirming lifted weight matches calculated panel weight within 10% variance. If significant weight discrepancy, lower panel and investigate before proceeding.

Safety considerations

Ensure all personnel except dogman clear of exclusion zones before rigging loads. Never allow workers to stand beneath suspended panels even momentarily. If rigging appears unstable or uneven loading observed, lower immediately and reassess.

Panel Rotation to Vertical Position

Begin controlled panel rotation from horizontal position toward vertical maintaining steady crane hoist speed. During rotation, panel center of gravity shifts creating changing load characteristics on crane. Watch for maximum load occurring when panel approximately 30-60 degrees from vertical. Monitor load moment indicator throughout rotation ensuring loads remain within crane capacity limits. Control rotation speed preventing rapid swinging that could create dynamic loads. Ground crew uses tag lines attached to panel bottom to control lateral movement preventing panel spinning or swinging. Never attach tag lines to crane hooks or rigging equipment. As panel approaches vertical position, slow rotation rate achieving gentle settling to vertical. Throughout rotation, continuously monitor wind conditions suspending operations immediately if wind speeds approach design limits (typically 10 m/s). If wind gusts cause panel swinging during rotation, hold panel at current angle until wind subsides before continuing. Communicate continuously between dogman and crane operator describing panel position and any instability requiring corrective action.

Safety considerations

Wind loads are maximum when panel at angles between horizontal and vertical. Monitor weather conditions continuously and be prepared to lower panel if conditions deteriorate. Ensure tag line handlers maintain safe distances preventing entanglement if lines slip.

Panel Positioning and Alignment

Once panel reaches vertical orientation, maneuver crane positioning panel at designated location marked on floor slab. Use surveyed floor marks indicating panel base position and alignment. Dogman guides crane operator using radio commands or hand signals directing panel movement to correct position. Ground crew manages tag lines controlling panel rotation and lateral position but never forcing panel against crane movements. Lower panel slowly until base contacts floor slab at marked location. Before releasing crane load, verify panel position matches design within acceptable tolerance (typically ±25mm horizontal position). Check panel alignment relative to adjacent panels and building gridlines using measuring tapes and visual sighting. If panel position incorrect, lift slightly and reposition before proceeding to bracing installation. Once positioned correctly, maintain crane support holding panel while bracing crew installs temporary bracing. Do not release crane load until adequate bracing is installed and inspected.

Safety considerations

Never allow workers to position themselves between panel and adjacent structures during positioning. Ensure adequate visibility for crane operator to see panel position and ground signals. If communication is lost, stop all movements until restored.

Temporary Bracing Installation

Install minimum two temporary braces to panel while crane maintains support. Position braces at locations specified in engineering design, typically upper third of panel height. Connect brace bottom ends to ground anchors installed during site preparation. Extend braces to panel connecting using embedded fixtures or brackets as designed. Initial brace installation provides coarse positioning holding panel approximately vertical. Install turnbuckles or adjustment mechanisms in braces allowing fine alignment adjustment. Using levels, adjust braces achieving panel plumb within 1:200 tolerance (50mm deviation over 10-metre height). Tighten brace connections to specified torque values ensuring secure fastening. Install additional braces if specified by design, typically minimum two braces oriented perpendicular to panel plane. Inspect all brace connections verifying secure attachment, proper orientation, and no damaged components. Structural engineer or designated competent person must inspect and certify adequate bracing before crane releases load. Only after certification obtained, crane slowly releases tension verifying braces support panel without movement or distress. Complete visual inspection after crane release confirming panel stability and no brace deformation.

Safety considerations

Workers installing braces at heights must use fall protection including harnesses and lanyards. Ensure braces do not create trip hazards across work areas. Never remove bracing until engineer certifies permanent connections provide stability.

Post-Erection Inspection and Documentation

Conduct comprehensive inspection of erected panel verifying position, plumb alignment, bracing installation, and overall stability. Measure panel position relative to design location documenting any deviations exceeding tolerance. Check panel plumb using levels at multiple locations verifying vertical alignment. Inspect bracing connections including fasteners, turnbuckles, and ground anchors for adequate installation and security. Photograph panel showing overall position, bracing configuration, and any irregularities requiring attention. Document panel identification number, erection date and time, weather conditions including wind speeds, actual panel weight measured by crane, and any issues encountered during lifting. Mark panel base indicating bracing installation date and prohibiting brace removal without authorization. Update panel erection sequence drawings showing completed panels and remaining panels for subsequent lifts. Verify exclusion zones remain in place around erected panels until permanent structural connections installed. Report any cracks in panels, damaged bracing components, or unstable conditions to structural engineer immediately for assessment. Maintain daily log recording all panel lifts including panel numbers, weights, wind conditions, crane configurations, and engineer certifications.

Safety considerations

Maintain barriers around erected panels preventing accidental contact that could disturb temporary bracing. Ensure temporary bracing is clearly marked preventing removal by other trades. Monitor weather forecasts and inspect bracing after high wind events.

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Frequently asked questions

What are the minimum concrete strength requirements before tilt-up panels can be lifted?

The National Code of Practice for Precast, Tilt-up and Concrete Elements specifies panels must achieve minimum 75% of specified 28-day compressive strength before lifting operations commence. This requirement ensures panels possess adequate strength to withstand lifting stresses without cracking or structural damage. Strength verification requires testing concrete cylinders cast from panel concrete and cured alongside panels under identical conditions. Cylinders are compression tested at intervals (typically 7, 14, and 21 days) with lifting authorized only after test results confirm the 75% threshold is met. For standard 32 MPa concrete panels in moderate weather conditions, this typically requires 10-14 days curing. Projects using accelerated curing techniques, heated enclosures, or high-early-strength concrete mixes may achieve adequate strength in 7 days, but always verify through cylinder testing not time estimates. The structural engineer must review test results and provide written certification that panels meet minimum strength requirements before any lifting operations. Never proceed with lifting based solely on elapsed time, as actual strength development varies with concrete mix design, curing conditions, and ambient temperatures. Lifting panels before adequate strength causes panel cracking during rotation, structural damage reducing design capacity, or catastrophic panel failure during the lift causing collapse and potential fatalities.

What wind speed limits apply to tilt-up panel lifting operations?

Australian standards and the National Code of Practice typically limit tilt-up panel erection when sustained wind speeds exceed 10 metres per second (36 km/h measured at panel height). This conservative limit recognizes that large panel surface areas create substantial wind loads, with panels acting as sails subjected to forces proportional to wind speed squared. During panel rotation from horizontal to vertical, wind loading characteristics change continuously with maximum loads occurring when panels are oriented 30-60 degrees from vertical. Panel surface area combined with height above ground creates overturning moments that must be resisted by crane capacity during lifting and temporary bracing after erection. Wind monitoring must use calibrated anemometers positioned at heights matching erected panel tops, not ground-level weather stations that underestimate winds at height. Real-time monitoring provides objective decision criteria requiring immediate suspension of operations when winds approach design limits. If wind speeds exceed limits during a panel lift, the panel must be lowered to the ground immediately rather than attempting to complete the erection. Lifted panels should not be left suspended waiting for wind to subside, as fatigue on crane components and rigging increases failure risks. Forecasted wind conditions must be checked before commencing daily operations, with lifting prohibited if forecasts predict exceedance of design limits during planned lift windows. Some projects specify lower wind limits (8 m/s) for particularly large or thin panels, or higher limits (12 m/s) for small, thick panels with reduced surface area - these variations must be determined by structural engineering analysis specific to each project.

How long must temporary bracing remain in place after panel erection?

Temporary panel bracing must remain installed and undisturbed until the structural engineer certifies that permanent structural connections provide adequate stability allowing safe brace removal. This typically occurs after roof structure is completed providing lateral restraint to panel tops, and after permanent panel base connections are installed securing panels to floor slabs or footings. For typical single-storey warehouse construction, temporary bracing remains in place for 2-4 weeks after panel erection while roof framing, purlins, and roof sheeting are installed. The specific duration varies with construction sequence, weather delays, and contractor progress. Under no circumstances should temporary bracing be removed based on elapsed time or visual appearance of stability - structural engineer certification is mandatory before any brace removal. Premature brace removal has caused multiple catastrophic panel collapses in Australian construction, with investigations finding that contractors removed bracing to facilitate subsequent trades' access before permanent stability was achieved. Each panel must be individually assessed by the engineer considering its specific connections, loading conditions, and surrounding structure before authorizing brace removal. Documentation must record which panels are cleared for brace removal and which remain dependent on temporary support. Workers must be trained that temporary bracing is critical safety equipment that must not be disturbed, relocated, or removed without specific engineering authorization. Any damage to bracing from construction activities, vehicle impact, or weather events must be reported immediately for engineering assessment and repair before continuing construction.

What qualifications and licenses are required for personnel involved in tilt-up panel lifting?

Tilt-up panel lifting requires multiple licensed and qualified personnel coordinating operations. The crane operator must hold a current high-risk work license for mobile crane operations (C2 license for cranes up to 100 tonne capacity or CN license for larger cranes) issued by the relevant state work health and safety regulator. Dogmen directing crane operations must hold current C6 (Dogging) high-risk work licenses authorizing them to perform slinging and directing crane operations. The structural engineer designing lifting operations, rigging systems, and temporary bracing must be registered with the relevant professional engineering board (RPEQ in Queensland, RPEQ equivalents in other states) with demonstrated competency in tilt-up construction. The site supervisor overseeing lifting operations should have construction management qualifications and extensive tilt-up experience, though specific licensing is not mandated. Riggers installing specialized lifting equipment may require Rigging qualifications (HRW licenses) depending on complexity of rigging systems being installed. All personnel must complete project-specific induction covering lift plans, emergency procedures, communication protocols, and individual responsibilities before participating in panel erection. The principal contractor must verify all licenses are current and relevant to work being performed, maintaining license records on site for inspection by regulators. Workers without required licenses must not perform any high-risk work including crane operation, dogging, or rigging activities. Recent prosecutions have specifically cited inadequate verification of worker qualifications as contributing factors in panel lifting incidents, with WorkCover inspectors requesting production of license documentation during site visits.

What emergency procedures should be in place for panel lifting operations?

Comprehensive emergency procedures for tilt-up panel lifting must address multiple scenarios including crane mechanical failure during lifts, sudden weather changes, panel instability after erection, medical emergencies in exclusion zones, and personnel trapped or injured by panels. The emergency response plan must include immediate shutdown procedures where crane operators can emergency-lower suspended panels to ground if mechanical failures occur or weather deteriorates rapidly. Site emergency assembly point must be designated well clear of potential panel collapse zones where all personnel can gather for accountability. Emergency contact information must be immediately accessible including structural engineer contact for stability concerns, crane service company for mechanical emergencies, emergency services (000), and company safety managers. First aid equipment and trained first aiders must be available on site with clear protocols for accessing injured workers in exclusion zones only after ensuring area is safe to enter. Communication systems must have emergency override protocols allowing any worker to immediately stop operations if hazards are observed. Panel instability after erection requires immediate engineering assessment with procedures for emergency re-bracing if panels show signs of movement or distress. Rescue procedures for workers injured in exclusion zones must account for potential instability preventing immediate access, with specialized rescue teams potentially required. All site personnel must participate in emergency procedure briefings before lifting operations with regular drills testing response effectiveness. Emergency procedures must be displayed at site notice boards and in crane operator cabins. Incident reporting procedures must capture near-misses and minor incidents for investigation preventing recurrence. WorkCover notification requirements for serious incidents must be understood by supervisory personnel ensuring legal compliance.

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Risk Rating

BeforeHigh

After ControlsLow

Key Controls

• Pre-start briefing covering hazards
• PPE: hard hats, eye protection, gloves
• Emergency plan communicated to crew

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Tilt-up Panel Lifting Safe Work Method Statement

What this SWMS covers

Why this SWMS matters

Hazard identification

Catastrophic Panel Collapse During or After Erection

Mobile Crane Tipping or Structural Failure During Lifts

Struck-by Suspended or Moving Panels During Positioning

Wind-Induced Panel Instability During and After Erection

Inadequate Ground Conditions Causing Crane or Brace Anchor Failure

Control measures

Engineered Lifting and Bracing Design by Qualified Structural Engineer

Exclusion Zones and Physical Barriers During Panel Lifts

Real-Time Wind Monitoring with Defined Suspension Criteria

Crane Capacity Verification and Load Monitoring

Documented Bracing Installation and Inspection Procedures

Communication Systems and Coordination Procedures

Personal protective equipment

Hard Hat Class B with Chin Strap

Steel Cap Safety Boots

High-Visibility Clothing Class D Day/Night

Safety Glasses with Side Shields

Safety Harness with Double Lanyard

Cut-Resistant Gloves

Inspections & checks

Before work starts

During work

After work

Step-by-step work procedure

Pre-Lift Engineering Review and Site Preparation

Crane Setup and Pre-Operational Checks

Panel Rigging and Initial Lift

Panel Rotation to Vertical Position

Panel Positioning and Alignment

Temporary Bracing Installation

Post-Erection Inspection and Documentation

Frequently asked questions

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