Guide To Safe Lifting & Propping

Safe Lifting & Propping of Precast/Tiltup Concrete Panels & Pipes
1.0 Overview
1.1 1.2 1.3 1.4 2.1 2.2 2.3 2.4 2.5 2.6 2.7 2.8 2.9 3.1 3.2 3.3 3.4 3.5 3.6 4.1 4.2 4.3 5.1 5.2 6.1 6.2 6.3 6.4 6.5 6.6 6.7 6.8 6.9 7.1 7.2 7.3 7.4 Introduction Safety and the Law - 1992 Health and Safety in Employment Act Safety Makes Sense Special Cautions Types of Lifts Types of Lifting Anchors Lifting Eyes / Clutches Anchor Identification Foot Anchor Identification Facelift Anchor Identification Reid Eye Anchor (REA) Identification 1.3t Edgelift Anchor (1ELA) Identification 2.5t, 7t & 10t Edgelift Anchor with Feet (ELAWF) Identification Installing Swiftlift Foot Anchors How Swiftlift Lifting Clutches Work Installing Swiftlift Eye Anchors Correct Installation of Reid 2.5, 7 & 10t Edgelift Anchors Correct Installation of Reid 1.3t Edgelift Anchors How Edgelift / Hairpin Type Clutches Work Effect of Sling Angle Effective Rigging Strongbacks Correct on site Handling & Jointing of Pipes Working Load Limits and Concrete Strength Common Modes of Failure Designing Safe Propping Configurations Selecting the Correct Prop Size Prop Working Load Limits Bolting Requirements Concrete Strength and Edge Distances Installation Process Retaining Walls Specific Design Removing Plastic Recess Formers Prop Dolly Panel Pinning Releasing Panels from the Casting Bed
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2.0 Anchors and Lifting Eyes / Clutches
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3.0 Anchor Installation
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4.0 Rigging and Safe lifting
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5.0 Pipe Lifting
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6.0 Reid Swiftbrace Props
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7.0 Tips & Tricks
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Copyright Reid Construction Systems 2007. All rights reserved. Moral rights asserted.
COMPANY BACKGROUND

1.0 Overview
PRODUCT CATALOGUE
1.1
Introduction
The recommended methods of use detailed in this document are consistent with the Approved Code of Practice for the Safe Handling, Transportation and Erection of Precast Concrete and focuses on the key elements of:~ Concrete lifting systems Types of cast in Anchors, how they work and their correct installation Rigging Lifting Installation Propping
ANCHORS & FASTENERS
Reid Construction Systems introduced the Swiftlift Concrete Lifting System to the Construction Industry in Australia in 1977 and in New Zealand in 1984.
REIDBAR & FITTINGS
Swiftlift is a safe, simple and very efficient system that uses cast in lifting anchors with a forged spherical head for lifting and handling pre-cast concrete elements. A special device known as a clutch or lifting eye fits over the cast in anchor to provide connection between the crane and the element to be lifted.
CONCRETE LIFTING SYSTEMS NIRVANA MODULAR WALL CASTING SYSTEM CAST-IN CHANNELS
Picture 1.1 Swiftlift Clutch and Anchor Head
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Other lifting systems utilise anchors made from high tensile steel, which can be less reliable than forged anchors. The Reid Swiftlift system is the most reliable and technically advanced concrete lifting system available. All Reid Swiftlift anchors comply with the Approved Code of Practice for the Safe Handling, Transportation and Erection of Precast Concrete. All Reid Swiftlift and Edgelift anchors are designed with a minimum Factor of Safety of 3 times the Working Load Limit (W.L.L). All ReidLifting Clutches are designed with a minimum safety factor of 5 times the Working Load Limit (W.L.L).
1.2
Safety and the Law - Health and Safety in Employment Act 1992
The principal object of the Health and Safety in Employment Act 1992 (HSE Act) is to prevent harm to employees at work. To do this it imposes duties on employers, employees, principals and others to promote excellent health and safety management by employers. It also provides for the making of regulations and codes of practice. The Approved Code of Practice for the Safe Handling, Transportation and Erection of Precast Concrete was developed by construction industry representatives to ensure safe work practices are promoted and become standardized normal work practices in precast factories and on building sites.
1.3
Safety Makes Sense

Every year hundreds of people are injured at work in factories or on construction sites. The Photos 1.1.1 on the next page are scenes of near miss and fatal incidents which could have been avoided by complying with the Approved Code of Practice.
1.4
Special Cautions
Reids Swiftlift and Edgelift Anchors must not be exposed to temperature extremes or welded in any form as this will render the system hazardous. Never attach anchors to reinforcing steel by spot welding.
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COMPANY BACKGROUND
PRODUCT CATALOGUE ANCHORS & FASTENERS REIDBAR & FITTINGS
A complex series of errors - site preparation, incorrect propping
CONCRETE LIFTING SYSTEMS NIRVANA MODULAR WALL CASTING SYSTEM
Incorrectly using Foot Anchor instead of Eye Anchor
Photo 1.1.1 Accidents
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CAST-IN CHANNELS

2.0 Anchors and Lifting Eyes / Clutches
Anchors are fixings that are cast in to the concrete element that allow for the connection to the lifting rig. These elements can be anything formed from concrete, such as manholes, pipes, beams, columns, wall panels, stairs, arches, etc. The safe lifting and placement of an element requires the following: The correct cast in The correct The correct element The correct The correct anchor type to be specified and number of anchors positioning of the anchors in the rigging of the lifting slings minimum concrete strength
Reid Swiftlift and Edgelift anchors are a simple, safe, and effective means of lifting and handling precast concrete elements.
2.1
Types of Lifts
There are two main types of lifts. Different types of anchors are used for each lift type. 1. Face Lift The initial lift is in line with the anchor. The initial lift puts the anchor in tension. Refer to Diagram 2.1.1 2. Edge Lift The initial lift is across the anchor. The initial lift puts the anchor in shear. Refer to Diagram 2.1.2
Diagram 2.1.1 Face Lift
Diagram 2.1.2 Edge Lift
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COMPANY BACKGROUND

2.2 Types of Lifting Anchors
Anchors are classified as either Facelift or Edgelift as described in Section 2.1. Facelift Anchors and Foot Anchors:
PRODUCT CATALOGUE
Both anchors are used for face lifting. Face lifting is the safest and most reliable method of lifting.
ANCHORS & FASTENERS
Facelift Anchor
Foot Anchor
REIDBAR & FITTINGS
Foot Anchors are cast into the face of the element with a recess former used to form the hollow into which the Clutch is placed to engage the head of the Anchor.
CONCRETE LIFTING SYSTEMS
The Anchor gains its capacity by developing a pull out cone in the concrete. The diameter of the cone at the face of the concrete is about 6 times the depth of the Anchor.
NIRVANA
Diagram 2.2.1 Facelift Anchor The distance to any edge and the length of the anchor are critical factors when using Facelift Anchors because both affect the lifting capacity. Reid make Facelift Anchors in sizes from 35mm long 1.3t anchors to 700mm long 30t anchors. Always use the longest posssible foot anchor available in any application.
MODULAR WALL CASTING SYSTEM

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CAST-IN CHANNELS

Edgelift Anchors:
Edgelift Anchors are cast into the side of the element with a recess former used to form the hollow into which the Clutch is placed to engage the head of the Anchor.
The foot of the Shear Bar stops the lifter pulling out when tilting up the panel. Correct installation of the shear bar is critical for it to work. Refer to section 3.3
Diagram 2.2.2 Edgelift Anchor Edgelift Anchors are Swiftlift Foot Anchors with a special eye at the foot to allow the addition of an extra reinforcing bar to increase the lifting capacity of the anchor in weak concrete or thin elements where Foot Anchors would not develop enough pullout capacity. Edgelift Anchors must be installed correctly to work as they are often installed in areas where edge distance is at a minimum and any error can be disastrous. They lift in shear to begin with and then tension as the element is rotated for placement. Refer to Section 3.3 for more information. Reid manufacture Edgelift Anchors in various sizes and types as shown in Diagram 2.2.3.
1.3t Edgelift Anchor
1.3, 2.5, 5 & 10t Eye Anchors Diagram 2.2.3 Edgelift Anchors
2.5, 7 & 10 Edgelift Anchors with feet
Edgelift Eye Anchors come as shown or in a number of different pre-assembled kits. The kits incorporate the anchor, recess former and shear bar or cage making for easier installation. Full details of these are contained in the Reid Concrete Lifting Design Manual. Edgelift Anchors have two lifting capacities, one for shear and one for tension. A Shear Bar (Refer to section 3.3) must be used with the 1.3t Edgelift Anchor and all Eye Anchors for tiltup shear lifts.
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COMPANY BACKGROUND

2.3 Lifting Eyes / Clutches
There are two main types of Lifting Clutches, or Eyes, which fasten to the head of the Anchor. Refer to Diagram 2.3.1
PRODUCT CATALOGUE ANCHORS & FASTENERS REIDBAR & FITTINGS
Swiftlift Clutches
Hairpin or Flat Anchor Clutches Diagram 2.3.1 Lifting Clutches
2.4
Anchor Identification
The NZ Code of Practice states, All lifting inserts embedded in concrete shall be clearly marked to enable their length and type to be identified after they have been cast into the element.
2.5
Foot Anchor Identification

Length Stamp: All Foot Anchors have the length of the anchor stamped on the anchor head. If there is no length stamp the anchor is not a Foot Anchor. Clutch Rating: This is the W.L.L of the lifting clutch that fits this anchor. Refer to Section 3.2 & 3.6
NIRVANA
Reid Logo
Reid Logo (back)
Clutch Rating / Load Group (tonnes) Anchor Length (mm)
Anchor Length (mm)
Clutch Rating / Load Group (tonnes)
Diagram 2.5.1 Foot Anchor
Diagram 2.5.2 Facelift Anchor
2.6
Facelift Anchor Identification

The product code stamped on the side of the head is used to identify the Clutch Rating, Anchor Type, and Length. For example: 5FLA130 = 5 tonnes maximum load, Facelift Anchor, 130 mm overall length. Refer to Diagram 2.5.2
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CAST-IN CHANNELS

2.7 Reid Eye Anchor (REA) Identification
Clutch Rating: This is the W.L.L of the lifting clutch that fits this anchor. Refer to Section 3.2 Reid Eye Anchors use additional reinforcing Hanger Bars to achieve tensile lift capacities in thin sections or low strength concrete. Refer to Section 3.3 There is no length stamp on an Eye Anchor because of the need for the Hanger Bar, which can vary in length. Reid Logo Clutch Rating (tonnes) Clutch Rating
Product Code
2.8
1.3t Edgelift Anchor (1ELA) Identification

The 1ELA has been designed specifically for use in thin concrete sections.
Diagram 2.7.1 Reid Eye Anchor
Product Code
Edge Anchor Identification Diagram 2.8.1 shows the marking on body of a Reid Edgelift Anchor.
2.9
2.5t, 7.0t and 10.0t Edgelift Anchor with Feet (ELAWF) Identification
Shape variations exist between the 2.5 tonne anchor and the 7 and 10 tonnes anchors due to different manufacturing processes. Diagram 2.8.1 Reid 1.3t Edgelift Anchor Clutch Rating: This is the first number of the product code. Edgelift Anchors use Hanger Bars to achieve the rated lift capacities in tension. Product Code NB: Eye Anchors and Edgelift Anchors must have additional reinforcing steel Hanger Bars installed. Refer to Sections 3.3 & 3.4 for more information.
Diagram 2.9.1 Edgelift Anchor with Feet
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COMPANY BACKGROUND

3.0 Anchor Installation
3.1 Installing Swiftlift Foot Anchors
Swiftlift Anchors are cast into the concrete with recess formers to create the void in the concrete permitting the lifting clutch to attach to the head of the anchor. Figure 3.1.1 shows the two main Foot Anchor installations. Recess formers may be plastic, steel, or rubber depending on application or casting process.
PRODUCT CATALOGUE ANCHORS & FASTENERS
Recess Former
REIDBAR & FITTINGS
PCHAIRS installed prior to casting concrete. Figure 3.1.1 Foot Anchor Installation
Puddle in placed as the concrete is cast and worked.
Photo 3.1.1 shows how the recess former looks installed in the concrete and Photo 3.1.2 shows the recess former removed and the anchor head exposed ready to receive the lifting clutch.
NIRVANA MODULAR WALL CASTING SYSTEM
Photo 3.1.1 Recess former in concrete See Sections 7.0 for removing plastic recess former.
Photo 3.1.2 Recess former removed
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CAST-IN CHANNELS

Table 3.1.1 gives the Working Load Limits of Foot Anchors for the given strength of concrete at time of lifting. Table 3.1.1 W.L.Ls for Foot Anchors
Anchor Load Group 1.3 1.3 1.3 1.3 1.3 1.3# 2.5 2.5 2.5 2.5 2.5 2.5# 5.0 5.0 5.0 5.0 5.0# 10.0 10.0 10.0# Anchor Length 35 45 55 66 85 120 55 65 75 90 120 170 95 120 150 170 240 150 170 340 Concrete Compressive Strength at Lift (fc) 15 MPa 0.55 0.77 1.02 1.30* 1.30* 1.30* 1.07 1.34 1.63 2.10 2.50* 2.50* 2.36 3.42 5.00* 5.00* 5.00* 5.20 6.57 10.00* 20 MPa 0.64 0.90 1.18 1.30* 1.30* 1.30* 1.24 1.55 1.88 2.42 2.50* 2.50* 2.73 4.16 5.00* 5.00* 5.00* 6.30 7.97 10.00* 25 MPa 0.71 1.00 1.30* 1.30* 1.30* 1.30* 1.38 1.73 2.10 2.50* 2.50* 2.50* 3.05 4.83 5.00* 5.00* 5.00* 7.32 9.26 10.00* 30 MPa 0.78 1.10 1.30* 1.30* 1.30* 1.30* 1.51 1.90 2.30 2.50* 2.50* 2.50* 3.34 5.00* 5.00* 5.00* 5.00* 8.27 10.00* 10.00*
Table 3.1.2 W.L.Ls for Facelift Anchors

Load Group Length 5 Anchor Length 100 Concrete Compressive Strength at Lift (fc) 15 MPa 3.66 20 MPa 4.44 25 MPa 5.00* 30 MPa 5.00*
130
5.00*
5.00*
5.00*
5.00*
#Standard length anchor - min concrete strength 10MPa will give maximum clutch lift capacity. *Maximum WLL of lifting clutch Min edge distance = 3 times anchor length without capacity reduction. Min anchor spacing = 6 times anchor length without capacity reduction. Min concrete strength at lift = 15MPa for non standard length anchors.
NB. It is important to understand that the actual capacity for a particular lift may be lower than the rating stamped on the anchor due to factors such as concrete strength, edge distances and proximity to other anchors.
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COMPANY BACKGROUND

3.2 How Swiftlift Lifting Clutches Work
PRODUCT CATALOGUE
Handle
Tab Diagram 3.2.2 Swiftlift Remote Release Clutch Clutch slot
ANCHORS & FASTENERS
Diagram 3.2.1 Swiftlift Clutch
Lift Direction
Tab is rotated over to sit on surface
REIDBAR & FITTINGS
Sling handle
2 Concrete Touching concrete Lift
Foot anchor depth varies 1 Diagram 3.2.3 Swiftlift Clutch Operation
Figure 1. The Lifting Clutch is attached to the Swiftlift Anchor by lowering the clutch slot over the anchor and rotating the tab until it rests on the concrete surface, with the tab on the side that will be uppermost when lifting. Figure 2. As the load is raised the Anchor takes the full load in tension. Figure 3. As the load rotates or if lifted with the anchor in shear, the clutch comes into contact with the concrete. This transfers the lifting force into the concrete and the anchor prevents the clutch slipping out of the recess. Figure 4. Lifting away from the tab is also safe provided the tab does not rise more than 30 from concrete surface.
NIRVANA
Lift
CAST-IN CHANNELS
30max
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Swiftlift Lifting Clutches are made in different sizes and rating to match the anchors. The correct clutch must be used with the correct anchor size, ie 2.5t clutch with 2.5t anchor. Table 3.2.1 gives details of the clutches available. Table 3.2.1 - Swiftlift Clutches
Product Code 1LE 2LE 5LE 10LE 20LE 32LE Description 1.3t Swiftlift Clutch 2.5t Swiftlift Clutch 5t Swiftlift Clutch 10t Swiftlift Clutch 20t Swiftlift Clutch 32t Swiftlift Clutch Working Load Limit (Tonnes) 1.3 2.5 5.0 10.0 20.0 32.0
3.3
Installing Swiftlift Eye Anchors

Eye Anchors are used to lift panels where the thinness of the concrete requires extra reinforcing steel (hanger bars) to be connected to the anchor to get the required lifting capacity. Eye Anchors come in 1.3, 2.5, 5, 10, 20 & 32t capacities. The length of hanger bar required with each of these anchors in 10MPa concrete is given in Table 3.3.1 Shear Bar Eye Anchor
Table 3.3.1 Hanger Bars Lengths Swiftlift Eye Anchors Working Load Limits 10MPa concrete(1)
Anchor 1.3 2.5 5.0 10.0 Bar Dia (mm) 8 12 16 20 Bar Length(1) (mm)
35 45
Hanger Bar
1000 1500 2000 2700
(1) Cut & bent length
Deformed bar or prestressing strand.
Hooked bars give better holding strength.
Diagram 3.3.1 Eye Anchor Installation
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COMPANY BACKGROUND

Shear Bars are available for 1.3 & 5t Edgelift Eye Anchors. Table 3.3.2 gives the correct Shear Bar to use with each anchor. Table 3.3.2 Shear Bars
Shear Bar Code 1 ELASB 5 ELASB120 5 ELASB Min Panel Thickness (mm) 80 120 150 Use with Anchor 1ELA 1REA 5REA 5REA 5ELASB
Table 3.3.3 gives lift capacities for Shear Bars.
PRODUCT CATALOGUE
Table 3.3.3 Shear Lift Capacity Uncracked Concrete WLL (tonnes)

Shear Lifter 1ELASB Panel Thickness (mm) 80 100 5ELASB120 120 150 150 175 200 250 2ELAWF 100 120 150 7ELAWF 120 150 175 200 10ELAWF 150 175 200 250 15 0.60 0.68 1.58 1.62 1.82 1.96 2.20 2.58 2.20 2.40 2.45 2.10 2.90 3.30 3.80 4.30 4.80 5.40 6.70 20 0.70 0.78 1.82 1.96 2.22 2.38 2.68 3.14 2.50 2.50 2.50 2.50 3.50 4.00 4.60 5.20 5.90 6.60 8.20 25 0.78 0.88 2.04 2.28 2.56 2.78 3.10 3.64 2.50 2.50 2.50 3.00 4.10 4.70 5.00 6.00 6.80 7.70 8.20 30 0.86 0.96
ANCHORS & FASTENERS
2.24 2.58 2.90 3.14 3.50 4.12 2.50
REIDBAR & FITTINGS
2.50 2.50 3.39 4.63 5.00 5.00 6.78 7.68 8.69 9.00
Shear Bars are used when egde lifting a thin panel. As shown in Section 3.2 when lifting in shear the lifting clutch bears against the concrete. In a thin panel this can break the edge out and cause the anchor to pull out during the tilt up operation. To prevent this a Shear Bar is installed as shown in Diagram 3.3.2. Care must be taken to ensure the feet of the Shear Bar are down as shown to ensure the load is properly transferred as far as possible into the concrete. When the tilt up operation begins the clutch will bear against the side of the recess and the shear bar.
NB: If the panel is placed flat during
Lift
Shear Bar placed against recess former
Diagram 3.3.2 Shear Bar Installation Clutch bears against Shear Bar preventing the edge from breaking
transportation or installation care must be taken to ensure it is not turned over as the shear bar will be on the wrong side. Use two shear bars facing opposite ways if the panel is to be lifted from both directions during transportation or installation.
CAST-IN CHANNELS
Diagram 3.3.3 Clutch and Shear Bar Operation
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3.4 Correct Installation of Reid 2.5t, 7t and 10t Edgelift Anchors with Feet
Edgelift Anchors with feet (ELAWF) are designed for edge lift tiltup applications . The anchors require hanger bars for vertical lifting as shown in diagrams 3.4.1 and 3.4.2 NB: When lifting to capacity on a 7t or 10t ELAWF an up-rated (7 or 10 tonne) clutch must also be used.
Hanger bars
Panel Edge Lifter
Recess former
Diagram 3.4.1 Edge Lifter installed in panel
The anchor must be orientated at right angles to the face of the panel, refer to Diagram 3.4.1, and have the appropriate two reinforcing bars or pre-stressing strands fitted through the pair of eyes at the base of the anchors. Refer to Diagram 3.4.2 and Tables on page 233. These bars must be bent down into the panel at an included angle between 35 to 45 and with a bend diameter of 5 bar diameters. Refer to Tables on page 233 for Hanger Bar length The specially designed feet provide superior anchorage in shear in both directions.
35 45
Diagram 3.4.2 Edge Lifter & Hanger Bars
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COMPANY BACKGROUND

Lift Lift Table 3.4.2 2ELAWF Tension Lift with Hanger Bars Lengths Working Load Limits unreinforced concrete(1)
15MPa W.L.L. tonnes 2.5 2.0 1.5 1.0 Bar Length(2) (mm) 635 510 380 255 25MPa Bar Length(2) (mm) 490 395 295 200
PRODUCT CATALOGUE
Table 3.4.1 2ELAWF Shear Lift Working Load Limit (t) Unreinforced concrete
Panel Thickness (mm) 100 120 150 Concrete Strength at time of lift 15MPa 2.20 2.40 2.50 20MPa 2.50 2.50 2.50 25MPa 2.50 2.50 2.50
ANCHORS & FASTENERS
Lift Table 3.4.3 7ELAWF Shear Lift Working Load Limit (t) Unreinforced concrete
Panel Thickness (mm) 120 150 175 200 Concrete Strength at time of lift 15MPa 2.10 2.90 3.30 3.80 20MPa 2.50 3.50 4.00 4.60 25MPa 3.00 4.10 4.70 5.00
(1) Min 100 mm thick panel (2) Cut & bent length HD12, 2 required per lifter. Refer to Diagram 3.4.3 Lift
REIDBAR & FITTINGS
Table 3.4.4 7ELAWF Tension Lift with Hanger Bars Lengths Working Load Limits unreinforced concrete(1)
15MPa W.L.L. tonnes 7 5 4 3 2 Bar Length(2) (mm) 1253 895 715 540 360 25MPa Bar Length(2) (mm) 973 695 555 415 280
Lift Table 3.4.5 10ELAWF Shear Lift Working Load Limit (t) Unreinforced concrete
Panel Thickness (mm) 150 175 200 250 Concrete Strength at time of lift 15MPa 4.30 4.80 5.40 6.70 20MPa 5.20 5.90 6.60 8.20 25MPa 6.00 6.80 7.70 9.00
(1) Min 120 mm thick panel (2) Cut & bent length HD12, 2 required per lifter. Refer to Diagram 3.4.3 Lift
NIRVANA
Table 3.4.6 10ELAWF Tension Lift with Hanger Bars Lengths Working Load Limits unreinforced concrete(1)
15MPa W.L.L. tonnes Bar Length(2) (mm) 1345 1210 1080 940 805 670 540 25MPa Bar Length(2) (mm) 1040 935 830 730 625 520 415
Cut & Bent length
10 9 8 7 6 5 4
35 45 Diagram 3.4.3 Hanger Bar Length
CAST-IN CHANNELS
(1) Min 500 mm thick panel (2) Cut & bent length HD16, 2 required per lifter. Refer to Diagram 3.4.3
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3.5 Correct Installation of Reid 1.3t Edgelift Anchors
The 1.3 tonne Edgelift Anchor (1ELA ) is suitable for thin panels and top lifting of pipes and tanks. When cast in the top edge and lifted in tension it requires no hanger bars. Table 3.5.1 gives working load limits for tension lifts.
shear bar hanger bar
For shear lifting a Shear Bar is required. Hanger Bar can be used to increase the lift capacity in 15MPa concrete and thin panels. L = 400mm min. Cut 800mm of HD8 Bar
35
45
Diagram 3.5.1 1 ELA with Hanger and Shear Bar
Shear Capacity
Lift
Limited to 400kg max by steel strength of anchor.
Lift Table 3.5.1 1ELA Vertical Lift Capacity(2) Working Load Limits (tonnes) No Hanger Bars
Panel Thickness (mm) 100 120 140 Concrete Strength at time of lift 15MPa 0.63 0.76 0.94 20MPa 0.77 0.92 1.14 25MPa 0.89 1.06 1.25*
* Maximum permissible clutch load
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COMPANY BACKGROUND

3.6 How Edgelift / Hairpin Type Clutches Work
PRODUCT CATALOGUE
2, 6 & 10 HPLE Clutch Diagram 3.6.1 Hairpin or Flat Anchor Clutch
1ELALE Clutch
ANCHORS & FASTENERS
Table 3.6.1 - Hairpin Clutches

Product Code 1ELALE 2HPLE 6HPLE* 10HPLE Clutch W.L.L. 1.3t 2.5t 6t* 10t
REIDBAR & FITTINGS
*This lifting clutch will be uprated to 7 tonnes in 2006 to develop full working capacity of 7ELAWF.
Figure 1. Recess former is levered out of concrete. Figure 2. The Lifting Eye is attached to the Edgelift Anchor by lowering the clutch slot over the anchor. Figure 3. Rotate the clutch tab until it rests on the concrete surface, with the tab on the side which will be uppermost when lifting. Figure 4. If shear loads are applied to the anchor then Shear Bars need to be installed for the correct load direction.
NIRVANA
The hole at the end at the handle is for attaching a remote line for disengaging.
The pin prevents release when lifting.
The handle is rotated within its sleeve to engage or withdraw the locking pin at the bottom.
The locking pin enters in its locating hole in the clutch, to engage in position.
CAST-IN CHANNELS
4 Diagram 3.6.2 Hairpin Clutch Operation
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4.0 Rigging and Safe Lifting
4.1 Effect of Sling Angle
Dont sling in this orange area.
The longer the slings the lower the load on the anchors. For example at an included angle of 170 the load on each sling is six times the weight of the actual load being lifted
NB Never make sling length shorter than the distance between two anchors. Diagram 4.1.1 Sling Angles
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COMPANY BACKGROUND

4.2 Effective Rigging
The effect of uneven slings from a central lifting point When lifting with 4 slings from a single point any slight variation in sling lengths will cause the load to be shared between 2 slings meaning individual anchor and sling loads will double.
NON STANDARD LIFT (Special equalization needed)
10 Tonnes
Using a lifting beam with four chains will ensure the legs are equally loaded.
REIDBAR & FITTINGS CONCRETE LIFTING SYSTEMS
N.B.: The lifting design above can only be used if the load of the panel can be taken by two diagonal anchors, in which case it is a Standard Lift. If not, a non standard lift with a spreader or lifting beam should be used.
STANDARD LIFT (All load designed to go on 2 anchors)
Using a lifting beam with 2 rolling blocks to ensure equal loading.
Using a triangular lifting beam with shackels and two sets of chains will ensure legs are equally loaded.
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CAST-IN CHANNELS

4.3 Strongbacks
Because of the complex shape of some panels they need to be strengthened before lifting. The most common method of strengthening panels is to bolt on external beams as strongbacks. Strongbacks must be properly designed and located to provide the necessary stiffness to prevent the panel from cracking. This requires the strongback to be rigid and connections to be located correctly. The strongback must be located to allow the rigging to operate without interference at all angles of the lift operation. Care must be taken when removing strongbacks as they are heavy and if allowed to fall or swing can cause considerable damage to panels, equipment and people.
Diagram 4.3.1 - Complex panel shapes needing strongbacks.
Common strongback sections are shown below.
Pryda Longreach Beam bolted to the concrete with Reid Hex Screw Bolts.
Steel Beam bolted to the concrete with Liebig bolts.
Double Steel Channel bolted to the concrete with Reid HSB12/230 Hex Screw Bolts.
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COMPANY BACKGROUND

5.0 Pipe Handling
100mm Shortening Hook
PRODUCT CATALOGUE
5.1
Correct on Site Handling & Jointing of Pipes

The sling The sling is made up as a two-legged chain sling with 2 Swiftlift Lifting Eyes and a shortening hook to enable one chain leg to be shortened. The sling is so constructed that either a symmetrical or asymmetrical lifting sling can be made.
1270 mm
mm 2000
ANCHORS & FASTENERS
Shortening Ring
730m m
UL1
UL2
Jointing the pipes
REIDBAR & FITTINGS
Transport, lowering and placing pipe in trench The pipes are handled with the sling in its symmetrical mode and are lowered into the trench close to the last pipe laid.
The crane hook is lowered so that both slings become slack. This enables the sling to UL1 to be shortened by placing the shortening ring onto the shortening hook. UL2 is then disconnected from the pipe to be jointed and attached to the furthest anchor on the previously laid pipe.
UL1
UL2
UL2
UL1
NIRVANA
1.2
mm in
in mm
1.2
1.2m
CAST-IN CHANNELS
Never make chain length shorter than the distance between two anchors.
Using a spreader between 2 chains will ensure no damage to top edge of the manhole riser
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5.2 Working Load Limits and Concrete Strength
Table 5.2.1 WLL vs Concrete Strength

Concrete Compressive Strength When Lifting 15MPa 1.3 1.3 1.3 1.3 1.3 1.3 2.5 2.5 2.5 2.5 2.5 2.5 5.0 5.0 5.0 5.0 5.0 10.0 10.0 10.0 35 45 55 66 85 120 55 65 75 90 120 170 95 120 150 170 240 150 170 340 0.55 0.77 1.02 1.30* 1.30* 1.30* 1.07 1.34 1.63 2.10 2.50* 2.50* 2.36 3.42 5.00* 5.00* 5.00* 5.20 6.57 10.00* 40MPa 0.90 1.27 1.30* 1.30* 1.30* 1.30* 1.50 1.90 2.50* 2.50* 2.50* 2.50* 3.86 5.00* 5.00* 5.00* 5.00* 9.55 10.00* 10.00*
Anchor Size
Anchor Length (mm)
*Maximum W.L.L. of Lifting Clutch Min edge distance = three times anchor length Min anchor spacing = six times anchor length Min concrete strength at time of lifting is no less than 40MPa
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COMPANY BACKGROUND

6.0 Reid Swiftbrace Props
Reid Swiftbrace Props are high capacity steel props suitable for the positioning and temporary stabilizing of: Precast elements Retaining walls Tiltup panels Block walls Formwork The props conform to NZS3404:1997 design standard and meet the requirements of the Approved Code of Practice for The Safe Handling and Erection of pre-cast Concrete. Nominal prop sizes: Fixed Length: 3.5m, 5m, 6.5m, 8m, and 10m. Telescopic: 5m to 8m with 500mm adjustment stops. All props have a screw thread fine adjustment length of approximately 500mm.
6.1
Common Modes of Failure.
REIDBAR & FITTINGS
Panels can break or props fail if the bracing configuration is not right. Diagram 6.1.1 shows the most common modes of failure.
CONCRETE LIFTING SYSTEMS NIRVANA MODULAR WALL CASTING SYSTEM
Diagram 6.1.1 Common Modes of Failure
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CAST-IN CHANNELS

6.2 Designing Safe Propping Configurations
The basis of design for wind force on a panel is shown in Diagram 6.2.1
F F
H
n H B
= Wind load on panel from NZS 4203. = Actual load in Prop. = Horizontal component of total load in Prop (F) actually resisting wind F . = Number of props per panel. = Panel height. = Bracing height. (0.67 x H ideally) = Brace angle (45 to 60)
W
F =
cos
F =
H
0.5 B
H
F must be less than the W.L.L of the Prop
Diagram 6.2.1 Wind force Calculation for Prop Design
To calculate the prop strength required you will need a copy of NZS4203 and follow the following steps. 1: Calculate the Wind Force (F ) on the panel using NZS4203. 2: Use the equations shown in Diagram 6.2.1 to calculate the resulting horizontal force (F ) on the prop at the height at which it is fixed to the panel (B ), and the actual force (F) in the prop.
w H H
The strength of the prop (refer to Table 6.4.1) must be greater than the load force (F).
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COMPANY BACKGROUND

6.3 Selecting the correct Prop size
The selection of prop length is made taking into account the panel height, the load the prop must carry, and the position of the anchoring point on the ground. Ideally the arrangement should be as shown in Diagram 6.3.1 below.
H = Panel Height B = 0.67 x H

H
1. 25
xB
len gth
REIDBAR & FITTINGS
Pr
op
Foot length = 0.75 x B
3
H
Diagram 6.3.1 Recommended Prop Configuration
Example: If the panel is 7m high. H=7 B = 0.67 x 7 = 4.7m Foot Length = 0.75 x 4.7 = 3.5m Prop Length = 1.25 x 4.7 = 5.9m
H
NIRVANA
Therefore a 6m prop is the ideal length however longer or shorter props may be used providing a safe configuration is achieved. Pay attention to attaching the prop high enough up the panel while keeping the prop angle at a maximum of 60. As a rule of thumb a 3/4/5 triangle shown in Diagram 6.3.1 is a good installation configuration guide. NB: Every panel must have at least two support props.

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CAST-IN CHANNELS

6.4 Prop Working Load Limits
The following tables are used as a quick guide to help select props for most common tiltup and precast applications.
Table 6.4.1 Working Load Limits(1)

Nom Prop Length (m) 3.5 3.5 5.0 6.5 8.0 10.0 5.0 8 .0 Max Size (m) 3.7 3.9 5.5 6.9 8.5 10.5 8.0 W.L.L (Tonnes) 1.6 5.0 2.7 1.7 1.2 1.8 0.7 @ 8.0m 3.1 @ 5.0m Telescopic Prop Type Light Duty Heavy Duty
(1). Based on 50% of the characteristic capacity of the steel section used to manufacture the prop.
Table 6.4.2 Maximum Panel Width Supported by 2 Props(1) (No knee bracing)
Nominal prop length (m) 3.5* 12.0 12.0 8.6 6.0 3.5** 12.0 12.0 12.0 12.0 12.0 12.0 12.0 10.6 8.1 12.0 11.8 8.7 6.6 5.2 4.2 3.3 7.5 5.8 4.6 3.7 3.0 2.5 10.8 8.5 6.9 5.7 4.8 4.1 12.0 12.0 12.0 12.0 8.3 6.5 4.0 1.8 5 6.5 8 10 Telescopic
Panel Height (m) 3 4 5 6 7 8 9 10 11 12 13
* Light Duty ** Heavy Duty (1). Additional panel width can be achieved by using 3 or more props per panel.
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COMPANY BACKGROUND

6.5 Bolting Requirements
Table 6.5.1 gives the minimum required bolt sizes for panel heights, for safe connection of the prop plates to the panel and support.
PRODUCT CATALOGUE
Table 6.5.1 Prop Bolting(1)

Panel Width (m)
Panel Height (m) 3 4 5 6 7 8 9 10 11 12 13 14 15
ANCHORS & FASTENERS
10
12
14
1. Based on NZS4203 for temporary structures. Key Liebig Safety Bolts AS15/15 or B15/45/105 Liebig Safety Bolts AS20/15 or B20/50
NIRVANA
Reid BA20/110 Specific Design
Example: A 5m high panel 10m wide requires Liebig AS20/15 or B20/50 Safety Bolts. (For further information see clause 2.3.4 of the for the Approved code of Practice for Handling Transportation and Erection of Precast Concrete.) It is very important that bolts are tightened to correct torque levels to ensure they are correctly set. Recheck bolts after strong winds.
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CAST-IN CHANNELS

6.6 Concrete Strength and Edges Distances
Any concrete to which the props are fixed must have a minimum of 15MPa compressive strength at time of fixing. Free edges must be treated with care to avoid edge break and loss of support. It is recommended that the distance to any free edge be at least 3 times the bolting depth.
6.7
Installation Process
The procedure of attaching the props to the panels and lifting of the panels into position varies with each site and the constraints of that site. The following procedure is recommend.
1: For safety it is best to attach the props to the panels prior to lifting. This avoids situations as shown in Photo 6.7.1 where a worker has to work from a ladder to drill and set the bolts. There is no guarantee that bolts will be correctly installed when a person is working at the limits of their reach and from an unsafe platform. When panels are transported to site it may not be possible to fix prop to the panel prior to lifting, in which case take all necessary steps to ensure the safety of the worker fixing the prop to the panel. It is very important that bolts are tightened to correct torque levels to ensure they are correctly set. Recheck bolts after strong winds. Photo 6.7.2 shows props fixed to the panel prior to the lift commencing.
Photo 6.7.1 Attaching Prop to Panel after lift
Photo 6.7.2 Props attached prior to lift
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COMPANY BACKGROUND

2: Lift the panel carefully into place, the feet of the attached props will need to be lifted out as the panel is positioned to avoid scraping along the ground. Small dollies can be used for this also (Refer to Section 7.2) Lift Lift foot end of prop or use dollies (refer to Section 7.2)
Prop Panel
Diagram 6.7.1 Lift Process
3: Once the panel is placed in its correct position and approximately vertical the feet of the props can be secured using suitable safety bolts and flat washer. As with the prop head the foot plate must be secured with suitable safety bolts tightened to the correct torque setting to ensure they do not shake loose.
Secure foot
NIRVANA
Diagram 6.7.2 Foot Bolting
4: Once the foot of the prop is secure the prop shaft is rotated to adjust its length to true the panel as shown in Diagram 6.7.3.
MODULAR WALL CASTING SYSTEM CAST-IN CHANNELS
Diagram 6.7.3 Truing Panel
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6.8 Retaining Walls
For retaining walls that are to be backfilled while propped the additional load of the backfilling must be allowed for in the selection of the correct prop. Please consult with a Reid Representative or your Engineer for advice.
6.9
Specific Design
Specific design of props and bolting will be required in the following conditions: Panels subject to additional loads from backfill, construction traffic or other additional loading. High wind situations, such as funnelling, exposed ridges, coastal exposure, etc. Long term propping requiring specific wind design in terms of NZS4203:1992. Any other condition that would exceed the 0.5kPa construction period wind load. If you are unsure about any aspect of propping, seek advice from a Reid Construction Systems Ltd Representative or your Engineer.
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COMPANY BACKGROUND

7.0 Tips and Tricks
The following ideas are practical tips and practices that can help make the erection of panels easier and faster.
PRODUCT CATALOGUE
7.1
Removing round plastic recess formers.

Many people use a screwdriver and hammer to chip out the plastic recess formers. This works but often leaves debris in the void that can interfere with the setting of the clutch or operation of the remote release.
ANCHORS & FASTENERS
It is better to use the method below.
The recess former as seen after concrete has set.
Using a self-drilling hex head wood screw and electric drill, drill into the centre of the recess former.
The screw will contact the centre of the lifting anchor head and the recess former will pop with ease.
The recess former is removed leaving a clean void and the collet, that is easily pulled off to allow the clutch to be set on the anchor.
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CAST-IN CHANNELS

7.2 Prop Dolly
Using a small wheeled Dolly on the prop foot when lifting panels allows the prop to move easily without damaging the floor or prop and eases the lift process as shown in Diagram 7.2.1.
Prop footplate
Dolly
Diagram 7.2.1 Prop Dolly
7.3
Panel Pinning
Either pin with rebar or bolt a block to slab to provide stop on panel line.
Diagram 7.3.1 Panel Pinning
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COMPANY BACKGROUND

7.4 Releasing panels from the casting bed
When lifting up panels from the casting bed it is very important not to overload the lifting anchors. Overloading can be caused by: Releasing agent not releasing properly. High panel to bed suction. Incorrectly located anchors. Surrounding water or other liquid preventing air getting under the panel. Panels bouncing with sudden release causing shock loading.
To prevent overloading the anchors the lift should be carried out as follows: 1. The crane takes up the slack of the rig and slowly increases the lifting force until the load on the anchors is only slightly above the force needed to lift the panel. 2. If the panel has not released, pry bars should be used to break the seal between the panel and casting bed. 3. Once the panel has released it can be lifted normally. Avoid using excessive lifting force with the crane as this will cause the panel to release suddenly and bounce hard down on the anchors and may result in panel and/or anchor damage.
Light tension
Diagram 7.4.1 Releasing panels from the casting bed
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CAST-IN CHANNELS

Guide To Safe Lifting & Propping

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Guide To Safe Lifting & Propping

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Safe Lifting & Propping of Precast/Tiltup Concrete Panels & Pipes

2.0 Anchors and Lifting Eyes / Clutches

3.0 Anchor Installation

4.0 Rigging and Safe lifting

5.0 Pipe Lifting

6.0 Reid Swiftbrace Props

7.0 Tips & Tricks

Safe Lifting & Propping of Precast/Tiltup Concrete Panels & Pipes

ANCHORS & FASTENERS

REIDBAR & FITTINGS

Picture 1.1 Swiftlift Clutch and Anchor Head

Safe Lifting & Propping of Precast/Tiltup Concrete Panels & Pipes

Safety Makes Sense

Safe Lifting & Propping of Precast/Tiltup Concrete Panels & Pipes

PRODUCT CATALOGUE ANCHORS & FASTENERS REIDBAR & FITTINGS

A complex series of errors - site preparation, incorrect propping

CONCRETE LIFTING SYSTEMS NIRVANA MODULAR WALL CASTING SYSTEM

Incorrectly using Foot Anchor instead of Eye Anchor

Photo 1.1.1 Accidents

Safe Lifting & Propping of Precast/Tiltup Concrete Panels & Pipes

Diagram 2.1.1 Face Lift

Diagram 2.1.2 Edge Lift

Safe Lifting & Propping of Precast/Tiltup Concrete Panels & Pipes

ANCHORS & FASTENERS

REIDBAR & FITTINGS

CONCRETE LIFTING SYSTEMS

MODULAR WALL CASTING SYSTEM

Safe Lifting & Propping of Precast/Tiltup Concrete Panels & Pipes

1.3t Edgelift Anchor

2.5, 7 & 10 Edgelift Anchors with feet

Safe Lifting & Propping of Precast/Tiltup Concrete Panels & Pipes

PRODUCT CATALOGUE ANCHORS & FASTENERS REIDBAR & FITTINGS

Hairpin or Flat Anchor Clutches Diagram 2.3.1 Lifting Clutches

CONCRETE LIFTING SYSTEMS

Foot Anchor Identification

Reid Logo (back)

Clutch Rating / Load Group (tonnes) Anchor Length (mm)

Anchor Length (mm)

MODULAR WALL CASTING SYSTEM

Clutch Rating / Load Group (tonnes)

Diagram 2.5.1 Foot Anchor

Diagram 2.5.2 Facelift Anchor

Facelift Anchor Identification

Safe Lifting & Propping of Precast/Tiltup Concrete Panels & Pipes

1.3t Edgelift Anchor (1ELA) Identification

Diagram 2.7.1 Reid Eye Anchor

Diagram 2.9.1 Edgelift Anchor with Feet

Safe Lifting & Propping of Precast/Tiltup Concrete Panels & Pipes

PRODUCT CATALOGUE ANCHORS & FASTENERS

REIDBAR & FITTINGS

Puddle in placed as the concrete is cast and worked.

CONCRETE LIFTING SYSTEMS

NIRVANA MODULAR WALL CASTING SYSTEM

Photo 3.1.2 Recess former removed

Safe Lifting & Propping of Precast/Tiltup Concrete Panels & Pipes

Table 3.1.2 W.L.Ls for Facelift Anchors

Safe Lifting & Propping of Precast/Tiltup Concrete Panels & Pipes

Tab Diagram 3.2.2 Swiftlift Remote Release Clutch Clutch slot

ANCHORS & FASTENERS

Diagram 3.2.1 Swiftlift Clutch

Tab is rotated over to sit on surface

REIDBAR & FITTINGS