GOOD PRACTICE GUIDELINES. Safe Work with Precast Concrete

Transcription

1 GOOD PRACTICE GUIDELINES Safe Wrk with Precast Cncrete CONSULTATION DRAFT Nvember 13, 2017 Page 1

2 Page 2

3 These guidelines ffer advice n the safe handling, transprtatin and erectin f precast cncrete. ACKNOWLEDGEMENTS WrkSafe New Zealand wuld like t acknwledge and thank the many stakehlders wh have cntributed t the develpment f this guidance. Page 3

4 KEY POINTS Precast cncrete is widely used in the New Zealand cnstructin industry. Handling, transprting and erecting precast cncrete are high-risk activities that have resulted in deaths and serius injuries t New Zealand wrkers. Every persn wrking with precast cncrete has health and safety duties. Everyne shuld clearly understand their rles and respnsibilities when wrking with precast cncrete. Page 4

5 TABLE OF CONTENTS GOOD PRACTICE GUIDELINES... 1 ACKNOWLEDGEMENTS... 3 TABLE OF CONTENTS... 5 SECTION 1: INTRODUCTION SCOPE HOW TO USE THESE GUIDELINES STRUCTURE OF GUIDELINES KEY TERMS DUTY HOLDER COMPETENT PERSON REASONABLY PRACTICABLE USE OF MUST AND SHOULD HSWA REFERENCES SECTION 2: ROLES AND RESPONSIBILITIES PERSON CONDUCTING A BUSINESS OR UNDERTAKING (PCBU) PRIMARY DUTY OF CARE PCBUs WITH OVERLAPPING DUTIES ADDITIONAL DUTIES FOR UPSTREAM PCBUS WORKER ENGAGEMENT, PARTICIPATION AND REPRESENTATION HOW A PCBU ENGAGES WITH WORKERS WORKERS OFFICERS OTHER PEOPLE AT THE WORKPLACE OTHER REGULATIONS SECTION 3: IDENTIFYING, ASSESSING AND MANAGING WORK RISKS RISK MANAGEMENT PLAN: IDENTIFY HAZARDS, ASSESS RISKS, SELECT CONTROL MEASURES RISK OF COLLAPSE OR CRUSH INJURIES Page 5

6 3.2.2 CONSIDER ALL HAZARDS ON SITE HAZARD IDENTIFICATION METHODS ASSESS WORK RISKS RECORD HOW RISKS ARE BEING MANAGED DO: PUT CONTROL MEASURES IN PLACE CHECK: MONITOR PERFORMANCE OF CONTROL MEASURES ACT: TAKE ACTION ON LESSONS LEARNT HEALTH AND SAFETY BY DESIGN SECTION 4: WORKER TRAINING WHAT COULD GO WRONG? TRAINING CUSTOMISE TRAINING PLANNING TRAINING: WHAT TO CHECK PLANNING TRAINING: WHAT TO CHECK (cntinued) WORKER COMPETENCE OTHER FACTORS AFFECTING WORKER COMPETENCE INDUSTRY QUALIFICATIONS TRAINING RECORDS RESPONSIBILITIES WHEN WORKING WITH TRAINEES SECTION 5: SITE MANAGEMENT SAFE SYSTEM OF WORK SITE ASSESSMENT BEFORE WORK BEGINS INITIAL SITE ASSESSMENT: WHAT TO CHECK EMERGENCY PLAN SECTION 6: DESIGN DESIGNERS DESIGN PHASES GENERAL CONSIDERATIONS TEMPORARY WORKS AND FALSEWORK DESIGN TO RESIST LOADS TEMPORARY SUPPORT FOUNDATIONS Page 6

7 6.4 SIZE AND SHAPE OF ELEMENTS DESIGN OF THE MANUFACTURING, TRANSPORT AND ERECTION PROCESSES RIGGING DESIGN CONCRETE WEIGHT AND STRENGTH MINIMUM STRENGTH FOR LIFTING FROM MOULDS FRICTION AND SUCTION LOADS DYNAMIC/IMPACT LOADS REPETITIVE LIFTING ADDITIONAL REINFORCEMENT STRONGBACKS LIFTING INSERTS LIFTING INSERT DESIGN: WHAT TO CHECK IMPOSED ACTIONS SECTION 7: DOCUMENTATION ON-SITE DOCUMENTATION CONSTRUCTION DOCUMENTS SHOP DRAWINGS SITE OFFLOADING AND ERECTION INFORMATION ERECTION DOCUMENTATION PROJECT-SPECIFIC CHECKLISTS AND FORMS PANEL DESIGN LIFT DESIGN REQUEST TILT-UP AND PRECAST CONCRETE DAILY CHECKLIST DOCUMENTATION FOR STRUCTURAL DESIGNER: WHAT TO CHECK OTHER DOCUMENTATION SECTION 8: MANUFACTURING WHAT COULD GO WRONG? THE PRECAST MANUFACTURER SHOP DRAWINGS AND APPROVALS PRECAST MANUFACTURER S DUTIES Page 7

8 8.4.1 TESTING OPTIONAL PRECAST MANUFACTURER S STATEMENT OF COMPLIANCE CURING COMPOUNDS AND RELEASE AGENTS SAFETY DATA SHEETS MOULDS AND CASTING BEDS MOULDS VERTICAL MOULDS AND TILTING MOULDS SURFACE FINISHES LIFTING FROM CASTING BEDS ASSEMBLY AND RELEASE MANUFACTURING TOLERANCES SECTION 9: HANDLING, STORING AND TRANSPORTING WHAT COULD GO WRONG? HANDLING, STORING AND TRANSPORTING THE HANDLING PROCESS CONCRETE STRENGTH FOR HANDLING AVOID MULTIPLE HANDLING AND RELOCATION STORING, STACKING AND SECURING DUNNAGE STACK AND STORE CORRECTLY STORAGE: WHAT TO CHECK STORAGE RACKS AND FRAMES TRANSPORTING TRANSPORT CONTRACTOR NEW ZEALAND TRANSPORT AGENCY (NZTA) COMPLIANCE PLAN AHEAD PLANT AND EQUIPMENT TRANSPORTATION: WHAT TO CHECK SITE-SPECIFIC TRAFFIC MANAGEMENT PLAN TRAFFIC MANAGEMENT: WHAT TO CHECK LOADING AND UNLOADING Page 8

9 9.5.7 DRIVER S RESPONSIBILITIES SITE ACCESS, CONDITIONS AND LIMITATIONS ON-SITE ACCESS: WHAT TO CHECK DRIVERS: WHAT TO CHECK SECTION 10: ERECTING WHAT COULD GO WRONG? ERECTOR/ERECTION TEAM (INSTALLER) ERECTION PLANNING ERECTION CREW PLANNING THE CONSTRUCTION AND ERECTION SEQUENCES ERECTION PLANNING: WHAT TO CHECK ERECTION PLANNING: WHAT TO CHECK (cntinued) PROPPING AND BRACING PROPS BRACES CHECK BRACING REGULARLY BRACE CONFIGURATION BRACING INSERTS FIXING INSERTS LEVELLING SHIMS CRANES AND LIFTING EQUIPMENT WHAT COULD GO WRONG? CRANE CONTROLLER, CRANE OPERATOR AND DOGMAN/RIGGER OPERATING SAFELY AND EFFECTIVELY TILT PANELS LIFTING OPERATIONS SUSPENDED SLABS LIFTING PRECAST CONCRETE ELEMENTS LOAD RESTRAINTS AND LIFTING LIFTING ELEMENTS FROM DELIVERY VEHICLE EXCLUSION ZONES Page 9

10 10.9 RIGGING LOAD EQUALISATION CHRISTMAS TREE LIFTING CONFIRM THE RIGGING SYSTEM LIFTING INSERTS AND CLUTCHES LIFTING INSERTS LIFTING CLUTCHES ROTATION APPENDICES APPENDIX A: STANDARDS AND OTHER TECHNICAL REFERENCES THAT MAY BE APPLICABLE TO PRECAST CONCRETE WORK APPENDIX B: GLOSSARY APPENDIX C: HEALTH AND SAFETY MANAGEMENT SYSTEM (HSMS) HSMS: WHAT TO CHECK APPENDIX D: HEALTH AND SAFETY REPRESENTATIVES, AND HEALTH AND SAFETY COMMITTEES HEALTH AND SAFETY REPRESENTATIVES HEALTH AND SAFETY COMMITTEES APPENDIX E: JOB SAFETY ANALYSIS TEMPLATE APPENDIX F: NOTIFICATIONS TO WORKSAFE APPENDIX G: DUTIES OF DESIGNERS, MANUFACTURERS, IMPORTERS, SUPPLIERS, INSTALLERS, CONSTRUCTORS AND COMMISSIONERS APPENDIX H: EXTRACT FROM SECTION B1.3.3 (PERFORMANCE) OF SCHEDULE 1 OF THE BUILDING CODE APPENDIX I: PANEL DESIGN FORM EXAMPLE APPENDIX J: LIFT DESIGN REQUEST FORM EXAMPLE APPENDIX K: TILT-UP AND PRECAST CONCRETE CHECKLIST EXAMPLE APPENDIX L: MANUFACTURER S STATEMENT OF COMPLIANCE FOR PRECAST CONCRETE ELEMENTS APPENDIX M: EXTRACTS FROM RELEVANT REGULATIONS DISCLAIMER Page 10

11 Figure 1: The PLAN-DO-CHECK-ACT apprach Figure 2: Examples f wrk-related health risks and health-related safety risks Figure 3: Hierarchy f cntrls Figure 4: Strngbacks supprting a large precast cncrete element Figure 5: A typical A-frame Figure 6: A-frames n a step-dwn trailer Figure 7: Panels, mass blcks and braces Figure 8: Examples f expansin inserts Figure 9: Levelling shims Figure 10: Wrker guiding panel using tag line Figure 11: Crane wrking radius Figure 12: Tw-crane lift Figure 13: Typical rigging system fr a precast cncrete element Figure 14: Precast cncrete elements with centre f gravity belw centre f lift Figure 15: Influence f nn-equalised rigging systems n distributin f lifting lads Figure 16: Examples f pssible rigging cnfiguratins fr lifting precast cncrete elements Figure 17: Christmas tree lifting Page 11

12 SECTION 1: INTRODUCTION These gd practice guidelines ffer advice fr keeping wrkers healthy and safe when handling, transprting and erecting precast cncrete. They als prvide guidance n hw t meet the requirements f the Health and Safety at Wrk Act SCOPE Precast cncrete is first cast and later mved int its final psitin. A precast element means any item made f precast cncrete (including, fr example, a beam, clumn, flr slab, wall panel, cladding panel, r pile). These guidelines are fr persns cnducting a business r undertaking (PCBUs), wrkers, upstream PCBUs (such as designers, manufacturers, suppliers, installers and imprters), and ther peple invlved in handling, transprting and erecting precast cncrete elements. The guidelines d nt cver design f the cmpleted structure, nr d they cver dismantling and demlishing precast cncrete structures. Risks t health and safety cme frm peple being expsed t hazards (surces f harm). These guidelines: utline the risks assciated with handling, transprting, and erecting precast cncrete describe gd practices fr managing thse risks prvide practical suggestins fr keeping wrkers safe and reducing the risk f injuries and fatalities. The mst significant hazards during wrk with precast cncrete elements are the uncntrlled cllapse f precast cncrete elements, and being crushed between a precast cncrete element and anther bject. These hazards may cause serius injuries r death. Factrs that may cntribute t uncntrlled cllapse r ther risks t wrkers include: faulty design adverse weather cnditins inadequate cncrete strength, due t: lifting befre the cncrete has reached its design strength manufacturing errrs Page 12

13 elements that have been damaged r weakened (eg by mdificatins r repairs) faulty lifting inserts r cnnectrs incrrect lifting and erectin practices, including unsafe rigging and inadequate r unsafe lifting equipment prly secured lads incrrect lading r unlading methds inadequate temprary strage facilities (eg racking systems, suspended flrs r beams) inapprpriate r unstable wrk areas fr cranes inadequate structural capacity f fundatins. These guidelines prvide advice fr dealing with these factrs. All wrk with precast cncrete must cmply with the requirements f the Health and Safety at Wrk Act 2015 (HSWA) and all relevant regulatins, including the Health and Safety in Emplyment Regulatins 1995 (HSE Regulatins), the Health and Safety in Emplyment (Pressure Equipment, Cranes, and Passenger Rpeways) Regulatins 1999 (PECPR Regulatins), and the Health and Safety at Wrk (General Risk and Wrkplace Management) Regulatins 2016 (GRWM Regulatins). 1.2 HOW TO USE THESE GUIDELINES These guidelines represent the current state f knwledge (the best available at the time f publicatin) n safe handling, transprtatin, and erectin f precast cncrete in New Zealand. They explain relevant legal requirements f HSWA and applicable regulatins, and als refer t ther legislatin such as the Building Cde. When planning hw t wrk with precast cncrete, always check any industryspecific guidance (eg New Zealand s Crane Safety Manual) as well. Sme requirements and recmmendatins in the guidelines are based n benchmarks set by New Zealand and Australian standards fr wrking safely with precast cncrete. The guidelines have als drawn n ther surces that address precast cncrete health and safety matters, including manufacturers instructins. Appendix A lists standards and ther technical references that may be relevant fr the design, manufacture and erectin f precast cncrete. T purchase standards, g t the Standards New Zealand website: r enquiries@standards.c.nz. Gd practice guidelines give advice they are nt legally binding. Hwever, if a duty hlder deviates frm gd practice they shuld have well-thught-ut reasns. The duty hlder shuld be able t explain why they tk alternative actin, and prvide apprpriate evidence t back this up. Gd practice guidelines may smetimes be cited by WrkSafe New Zealand (WrkSafe) as an expected standard f practice if pr practice is being alleged. They can be used in legal prceedings as evidence f whether r nt a duty r bligatin under HSWA has been cmplied with. Page 13

14 1.3 STRUCTURE OF GUIDELINES The guidelines are divided int ten sectins: Sectins 1 and 2 intrduce key terms and cncepts, including rles and respnsibilities under HSWA. Sectin 3 cvers identificatin, assessment and management f wrk risks. Sectin 4 briefly cvers wrker training and identifies factrs that can affect wrker cmpetence. Sectins 5 10 cver site management, design, manufacturing, handling, transprting, string, and erecting. Key hazards are listed at the start f several sectins. Hwever, there may be hazards at yur wrkplace that are nt identified in the lists f key hazards in these guidelines. S yu will still need t identify and assess the health and safety risks arising frm yur wn wrk. The appendices prvide additinal infrmatin, including a glssary f terms, and resurces such as templates and checklists. 1.4 KEY TERMS These guidelines use terms that are in cmmn use in New Zealand. Key terms are explained belw. The glssary in Appendix B explains ther technical and legislative terms used thrughut the guidelines. WrkSafe is aware that the cnstructin and manufacturing sectrs smetimes use different terms t refer t the same bject r practice. Wherever pssible, the guidelines identify these alternative terms. Fr example, an in-grund r n-grund mass blck is als referred t as a deadman; a lifting insert may als be knwn as a lifting anchr DUTY HOLDER A duty hlder is a persn wh has a duty under HSWA. There are fur types f duty hlders PCBUs, fficers, wrkers and ther persns at wrkplaces. Fr mre infrmatin WrkSafe s special guide Intrductin t the Health and Safety at Wrk Act COMPETENT PERSON In these guidelines, a cmpetent persn is a persn wh has the relevant knwledge, experience and skill t carry ut a particular task using apprpriate techniques and prcedures; and: Page 14

15 has a relevant qualificatin prving that they have the knwledge, experience, and skill required; r their PCBU has evidence (such as training recrds) demnstrating that the persn has the required knwledge, experience, and skill REASONABLY PRACTICABLE There are tw parts t reasnably practicable : Yu first cnsider what is pssible in yur circumstances t ensure health and safety. Yu then cnsider, f these pssible actins, what is reasnable t d in yur circumstances. Yu need t achieve a result that prvides the highest prtectin that is reasnably practicable in yur circumstances. Fr mre infrmatin WrkSafe s fact sheet Reasnably Practicable USE OF MUST AND SHOULD Term Definitin Must Legal requirement that has t be cmplied with. Shuld Recmmended practice r apprach. Table 1: Requirements in this guidance 1.5 HSWA REFERENCES References t relevant sectins f HSWA are in shaded bxes. Page 15

16 SECTION 2: ROLES AND RESPONSIBILITIES Everyne has respnsibilities under the Health and Safety at Wrk Act 2015 (HSWA). All PCBUs must ensure, s far as is reasnably practicable, the health and safety f wrkers and that ther peple are nt put at risk frm the wrk f the business r undertaking. This is the primary duty f care. HSWA defines the rles and respnsibilities f different duty hlders. These include PCBUs, fficers, wrkers and ther persns at wrkplaces. Fr mre infrmatin WrkSafe s special guide Intrductin t the Health and Safety at Wrk Act PERSON CONDUCTING A BUSINESS OR UNDERTAKING (PCBU) A PCBU is a persn cnducting a business r undertaking. In mst cases a PCBU will be an rganisatin (eg a business entity such as a cmpany), althugh a PCBU may be an individual persn (eg a sle trader). Businesses are usually run t make a prfit - fr example, a precast cncrete manufacturing business Undertakings are usually nt prfit-making r cmmercial fr example, a gvernment department r a schl A client, a head cntractr, a sub-cntractr and a self-emplyed persn at a precast peratin are all PCBUs. EXAMPLES OF A PCBU is respnsible fr cnsulting with designers and main cntractrs t make sure that health and safety matters are cnsidered in all aspects f precast cncrete wrk utlines expectatins fr cntractrs t develp and implement relevant prject-specific safe wrk practices and health and safety management systems (HSMSs; see Appendix C f these guidelines) ensures that cmpetent peple are engaged t carry ut the wrk. The client will ften engage a head cntractr t manage a cnstructin prject. Page 16

17 The head cntractr The head cntractr managing a cnstructin prject is usually respnsible fr crdinatin n-site, and mnitrs and liaises with key parties during cnstructin. WrkSafe expects the PCBU at the tp f a cntracting chain t be a leader in encuraging and prmting gd and health and safety practices thrughut the chain. The head cntractr s rle includes: sharing infrmatin abut the site reviewing site-specific dcumentatin, such as shp drawings ensuring that health and safety prcedures r prcesses are in place, including fr emergencies making sure that adequate training and cmmunicatin practices are in place planning all aspects f the site wrk t ensure precast deliveries, handling and temprary wrks are carried ut safely advising sub-cntractrs f specific requirements fr handling, transprt and erectin ensuring that cntractrs develp and put in place safe wrk practices and HSMSs representing the client cnsulting and c-rdinating with ther PCBUs such as designers, precast manufacturers, transprt cntractrs and crane cntracting businesses thrughut the duratin f the prject. Rles and respnsibilities f ther PCBUs (eg designers, manufacturers, erectrs and transprt cntractrs) are utlined in the relevant sectins f these guidelines PRIMARY DUTY OF CARE A PCBU has the primary duty f care the primary respnsibility fr peple s health and safety at wrk. The primary duty f care includes, s far as is reasnably practicable: prviding and maintaining a physical and psychlgical wrk envirnment that is withut risks t health and safety safe plant and structures safe systems f wrk ensuring safe use, handling and strage f plant, structures and substances prviding adequate and accessible facilities fr wrkers Page 17

18 prviding infrmatin, supervisin, training, and instructin necessary t prtect all persns frm risks t their health and safety frm wrk mnitring wrkers health and wrkplace cnditins t prevent injury r illness. Further, a PCBU managing r cntrlling a wrkplace must als ensure, s far as is reasnably practicable, the wrkplace, the means f entering r exiting the wrkplace, and anything arising frm the wrkplace are withut health and safety risks t any persn. Fr example, a PCBU shuld secure a cnstructin site each night s that unauthrised peple cannt get in PCBUS WITH OVERLAPPING DUTIES Mre than ne PCBU can have a duty in relatin t the same matter. Where this happens the PCBUs have verlapping duties. This might happen in: a shared wrkplace (eg a building site), where mre than ne PCBU and its wrkers cntrl and influence the wrk n site a cntracting chain, where cntractrs and sub-cntractrs prvide services t a head cntractr and client (althugh they dn t necessarily share the same wrkplace). PCBUs that share n cntractual relatinship may still share verlapping duties when they wrk n the same site. PCBUs must discharge their verlapping duties t the extent they have the ability t influence and cntrl the matter. Where duties are shared, they must cnsult, cperate with, and c-rdinate activities with ther PCBUs t meet their shared duties. EXAMPLE A PCBU must ensure that: adequate first aid equipment is prvided fr the wrkplace each wrker has access t the equipment and access t first aid facilities an adequate number f wrkers are trained t administer first aid at the wrkplace; r wrkers have access t an adequate number f ther persns wh have been trained t administer first aid. The head cntractr and crane sub-cntractr n a cnstructin site are bth PCBUs. This means that they bth have t ensure access n site t first aid equipment, first aid facilities and peple wh can administer first aid. The head cntractr decides t prvide the first aid facilities (including equipment and first aiders) n the cnstructin site. The head cntractr and the crane subcntractr agree that if the crane sub-cntractr s wrkers need first aid while n site they will use the cnstructin site s first aid facilities. This is an example f a PCBU entering int a reasnable agreement with anther PCBU t meet the duty t prvide first aid t wrkers. Page 18

19 Fr mre infrmatin WrkSafe s quick guide Overlapping Duties WrkSafe s fact sheet Reasnably Practicable ADDITIONAL DUTIES FOR UPSTREAM PCBUS PCBUs in the supply chain are knwn as upstream PCBUs. Upstream PCBUs have a duty t ensure, s far as is reasnably practicable, that the wrk they d r the things they prvide t ther wrkplaces dn't create health and safety risks. Sectins f HSWA specify the additinal duties f upstream PCBUs wh: > design plant, substances r structures > manufacture plant, substances r structures > imprt plant, substances r structures > supply plant, substances r structures > install, cnstruct r cmmissin plant r structures. Upstream PCBUs can influence and smetimes eliminate health and safety risks thrugh designing r manufacturing prducts that are safe fr the end user. Imprters must ensure imprted gds meet all New Zealand regulatry requirements. Upstream PCBUs have duties under HSWA arund testing, analysis, and infrmatin prvisin. Fr example, an upstream PCBU must prvide infrmatin n hw t use the structure, substance, r plant in a way that is safe and healthy t each persn they prvide it t. The dwnstream PCBU may engage with that upstream PCBU t make sure the dwnstream PCBU s needs are understd. Dwnstream PCBUs have a duty t ensure a safe and healthy wrking envirnment. They shuld cnsider health and safety implicatins and make reasnable enquiries abut structures, substances and plant they are buying r cmmissining fr use at wrk. This is particularly s where the dwnstream PCBU buys frm an unfamiliar r verseas supplier, buys in bulk, r cmmissins a structure. If a PCBU identifies a design r manufacturing fault that has cntributed t a health and safety risk at wrk, they shuld raise that with the designer, manufacturer, imprter, r supplier. The PCBU will als have t manage that risk WORKER ENGAGEMENT, PARTICIPATION AND REPRESENTATION All PCBUs must engage with their wrkers in wrkplace health and safety, s far as is reasnably practicable. PCBUs can ensure a safe wrkplace mre effectively when everyne invlved in the wrk: cmmunicates with each ther t identify hazards and risks talks abut any health and safety cncerns wrks tgether t find slutins. Page 19

20 PCBUs have tw main duties under HSWA: t engage with wrkers n health and safety matters that affect r are likely t affect them, s far as is reasnably practicable t have practices that give wrkers reasnable pprtunities t participate effectively in the nging imprvement f wrkplace health and safety. PCBUs are expected t have deliberate, planned ways t engage and supprt participatin. Each PCBU can determine the best way t meet its duties, depending n wrkers views and needs, the size f the rganisatin and the nature f its risks HOW A PCBU ENGAGES WITH WORKERS A PCBU engages with wrkers by: sharing infrmatin abut health and safety matters s that wrkers are wellinfrmed, knw what is ging n and can cntribute t decisin-making giving wrkers reasnable pprtunities t have a say abut health and safety matters listening t and cnsidering what wrkers have t say giving wrkers pprtunities t cntribute t the decisin-making prcess relating t a health and safety matter cnsidering wrkers views when decisins are being made updating wrkers abut what decisins have been made. If wrkers are represented by an HSR, engagement must invlve that representative. Health and Safety Representatives (HSRs) and Health and Safety Cmmittees (HSCs) are tw well-established methds f representatin; see Appendix D fr mre infrmatin. Wrkers can als be represented by unins, cmmunity r church leaders, lawyers, respected members f ethnic cmmunities, r peple wrking n specific prjects. Part 3 f HSWA cvers wrker engagement, participatin, and representatin Fr mre infrmatin WrkSafe s interpretive guidelines Wrker Representatin thrugh Health and Safety Representatives and Health and Safety Cmmittees WrkSafe s gd practice guidelines Wrker Engagement, Participatin and Representatin WrkSafe s pamphlets: Wrker Representatin Health and Safety Cmmittees Health and Safety Representatives Page 20

21 2.2 WORKERS A wrker is an individual wh carries ut wrk in any capacity fr a PCBU and includes emplyees, cntractrs, sub-cntractrs, apprentices and trainees, and vlunteer wrkers. Wrkers respnsibilities include: taking reasnable care f their wn health and safety taking reasnable care that what they d (r fail t d) des nt cause harm t any ther persn c-perating with any reasnable health and safety plicy r prcedure f the PCBU cmplying, s far as is reasnably able, with any reasnable instructin given by the PCBU, s the PCBU can cmply with the law in relatin t persnal prtective equipment (PPE): using r wearing PPE in accrdance with any infrmatin, training r reasnable instructin given by the PCBU nt intentinally misusing r damaging the PPE telling the PCBU when they becme aware the PPE is damaged r defective, r when it needs t be cleaned r decntaminated. Fr mre infrmatin WrkSafe s fact sheets Wrker health and safety rights and respnsibilities, available in English, Māri, simplified Chinese, Hindi, Saman and Tngan OFFICERS An fficer is a persn with a specific rle in an rganisatin (such as a cmpany directr) r a persn with the ability t exercise significant influence ver the management f the business r undertaking. Organisatins can have mre than ne fficer. Officers culd include, fr example, the chief executive r directr f a scafflding cmpany. Officers have a duty t ensure the PCBU cmplies with its duties under HSWA. Each fficer has a duty it is nt a jint duty. As part f this duty, fficers must exercise their due diligence and take reasnable steps t ensure the PCBU has apprpriate resurces and prcesses t meet their health and safety duties, and verify that thse resurces and prcesses are used. 2.4 OTHER PEOPLE AT THE WORKPLACE Other peple at a wrkplace must take reasnable care f their wn health and safety and ensure that they d nt adversely affect thers health and safety. Page 21

22 Other peple at a wrkplace ptentially at risk frm wrk activities include vlunteers, custmers, passers-by and visitrs. 2.5 OTHER REGULATIONS As well as cmplying with HSWA requirements, wrk with precast cncrete must cmply with ther relevant regulatins, including the HSE Regulatins, the PECPR Regulatins and the GRWM Regulatins. These regulatins are referred t thrughut these guidelines. Fr example, the GRWM Regulatins set ut a number f duties arund general wrkplace issues, including: facilities first aid persnal prtective equipment (PPE) emergency plans. Other regulatins cver different aspects f wrk health and safety. Fr example, the HSE Regulatins relevant t precast cncrete wrk include requirements relating t nise, machinery, wrking at height, and scafflding. Page 22

23 SECTION 3: IDENTIFYING, ASSESSING AND MANAGING WORK RISKS Risks t health and safety arise frm peple being expsed t hazards (anything that can cause harm). Risk management is nt just hazard-sptting. Identify all risks befre wrk cmmences and put cntrl measures in place. Invlve wrkers in this prcess. Make sure wrkers understand the risks and hw the cntrl measures shuld be used. 3.1 RISK MANAGEMENT Due t its size and mass, precast cncrete pses a significant risk t anyne wrking with it and t ther peple in the wrkplace. PCBUs must manage all health and safety risks. This will invlve cnsulting, cperating and c-rdinating with ther PCBUs. PCBUs must als engage with wrkers and their representatives when identifying and assessing risks, and when deciding hw t eliminate r minimise the risks. Identify hazards and then assess which wrk risks t take care f first. Wherever pssible, identify health and safety risks early and deal with them at the design stage. See Sectin 3.6 f these guidelines: Health and Safety by Design. Sectin 30 f HSWA cvers management f risks T manage risks: identify hazards that culd reasnably freseeably create a risk t health and safety eliminate the risk s far as is reasnably practicable if it is nt reasnably practicable t eliminate the risk, minimise the risk s far as is reasnably practicable maintain the implemented cntrl measures s they remain effective review and if necessary revise cntrl measures t maintain, s far as is reasnably practicable, a wrk envirnment that desn t have risks t health and safety. Page 23

24 WrkSafe encurages PCBUs t use the PLAN-DO-CHECK-ACT apprach shwn in Figure 1 t assess, manage, mnitr and review wrk risks. Engage with wrkers and their representatives at every step. Figure 1: The PLAN-DO-CHECK-ACT apprach 3.2 PLAN: IDENTIFY HAZARDS, ASSESS RISKS, SELECT CONTROL MEASURES Wrk has the ptential t harm a persn s health, and a persn s health can affect safety at wrk. Identify hazards which culd injure r harm anyne during any stage f precast cncrete wrk. Risks need t be cntrlled effectively even thugh harm may nt be evident fr mnths r years. Lk at the fllwing areas when cnsidering the effects f wrk n peple s health: Physical hazards (eg nise, vibratin) Bilgical hazards (eg bacteria, viruses) Chemical hazards (eg adhesives) Ergnmic hazards (eg manual handling) Psychscial hazards (eg bullying, tight deadlines, ther stress factrs). Page 24

25 Figure 2 shws examples f wrk-related health risks and health-related safety risks. Figure 2: Examples f wrk-related health risks and health-related safety risks Page 25

26 3.2.1 RISK OF COLLAPSE OR CRUSH INJURIES Significant harm can be caused by: uncntrlled cllapse f precast cncrete elements, including while elements are temprarily braced r when braces are being mdified r remved a persn being caught between a precast cncrete element and anther bject (eg mbile plant) while elements are being handled. The advice in these guidelines will help t minimise the chance f these situatins ccurring CONSIDER ALL HAZARDS ON SITE Identify hazards, risks and the related cntrl measures befre wrk begins s that they are ready t put in place when needed. Cnsider all hazards n site, including places where peple culd fall, hazardus materials and hazards assciated with undergrund and verhead services (eg gas, water, strm water, sewerage, telecmmunicatins, electricity). Other hazards assciated with precast cncrete wrk are shwn in the What culd g wrng? tables thrughut these guidelines. Be familiar with hazards and risks assciated with manufacturing and cnstructin wrk in general, fr example: Nise: many manufacturing and cnstructin tasks, tls and equipment prduce high nise levels, which can lead t hearing damage. Vibratin: repeated vibratins frm hand and pwer tls can cause permanent injuries t bld vessels, nerves and jints. Silica dust: silica is a txic substance cmmnly fund n cnstructin sites in materials such as cncrete, bricks, rcks, stne, sand and clay. Dust cntaining silica is created when these materials are cut, grund, drilled r therwise disturbed. Expsure t respirable crystalline silica can cause serius lung disease. Fatigue: fatigue is a state f physical and/r mental exhaustin (extreme tiredness) which reduces a persn s ability t stay alert and wrk safely. Fatigue is a wrk risk that bth PCBUs and wrkers must manage. Fatigued wrkers may make mistakes that lead t wrk incidents and injuries. Everyne shuld learn t recgnise the signs and symptms f fatigue HAZARD IDENTIFICATION METHODS Methds t identify hazards include: wrkplace inspectins culd smene be injured by precast cncrete activities, r culd yur wrk create hazards fr thers n site? lking at guidance, standards and industry resurces studying recrds f incidents, accidents and near misses at yur wn and ther wrkplaces Page 26

27 reading instructin manuals and chemical safety data sheets asking qualified prfessinals (eg engineers, ccupatinal hygienists) t assist lking at: yur wrk prcesses (eg what harmful substances d yu use r generate?) the wrkplace itself (eg grund cnditins, undergrund services) wrker behaviur, including hw equipment is used ASSESS WORK RISKS PCBUs must assess and manage wrk risks, taking the views f wrkers and their representatives int accunt. Decide which wrk risks need t be dealt with first and chse effective cntrl measures t manage them. PCBUs must eliminate risks s far as is reasnably practicable. If a risk can t be eliminated, it must be minimised s far as is reasnably practicable. Cnsider whether a small incident culd escalate t a serius situatin. Fr example, culd failure f a single prp supprting a precast cncrete element lead t a prgressive cllapse f adjining elements? Certain risks must be dealt with in a particular way. Fr example, there are specific requirements in the GRWM Regulatins abut managing risks assciated with wrking with raised bjects and bjects that may fall frm height. GRWM Regulatins 24 and 25 specify that a PCBU must manage risks assciated with: wrk being dne under any raised r lifted bject (including bjects lifted by crane), and bjects that may fall frm height, such as equipment, material, and tls. PCBUs must fllw a prescribed risk management prcess t manage these risks. See Sectin 10.7 (Lifting Operatins) fr mre infrmatin. If PCBUs can t eliminate these risks, they must minimise the risks, s far as is reasnably practicable RECORD HOW RISKS ARE BEING MANAGED It is gd practice t keep written recrds f hw wrk risks are being managed. When reviewing yur risks, lk at these recrds. Yu can als refer t the recrds when training wrkers abut risks and cntrl measures. Page 27

28 3.3 DO: PUT CONTROL MEASURES IN PLACE As sn as pssible after deciding what the mst effective cntrl measures are: put the cntrl measures in place make sure that wrkers knw abut the ptential risks, what the cntrl measures t manage the risks are and why it s imprtant t use them, and hw t apply them review and update emergency prcedures/plans if needed. Sme cntrl measures are mre effective than thers. The hierarchy f cntrls in Figure 3 ranks cntrl measures frm mst t least effective. Figure 3: Hierarchy f cntrls If the risk is nt specified in regulatins, the PCBU decides hw t manage the risk. Find ut if there are widely used cntrl measures (eg industry standards) fr particular risks. The PCBU shuld check whether these cntrl measures will effectively manage their risks. Eliminatin Eliminatin is the mst effective cntrl. First the PCBU shuld always try t eliminate a risk by remving the surce f harm, if this is reasnably practicable. Fr example, by remving faulty lifting equipment r a brken A-frame. If eliminatin is nt reasnably practicable, the PCBU minimises the risk s far as is reasnably practicable. One r a cmbinatin f the fllwing appraches can be used: 1 1 Fr prescribed risks, ne r a cmbinatin f these appraches must be used. Page 28

29 Substitutin Use an alternative design, prduct, r wrk practice that decreases the risk. Fr example: use a larger crane use a different prduct. Islatin Islatin prevents cntact with r expsure t the risk. Fr example: stand (erect) precast cncrete panels n a day when the nly wrkers n site will be the team ding the erectin. Engineering cntrl measures Use physical cntrl measures that include mechanical devices r prcesses. Fr example: build panels f a different size r shape change the prpping design t reduce the risk. Administrative cntrl measures EXAMPLE Use safe methds f wrk, prcesses r prcedures designed t minimise risk. Fr example: cmplete a lift plan develp a plicy fr dealing with fatigue. A fatigue plicy shuld cver: maximum shift length and average weekly hurs prcedures fr reprting fatigue prcedures fr managing fatigued wrkers wrk-related travel. The plicy culd mentin that the Land Transprt Act 1998 sets limits t the wrktime hurs fr drivers f particular vehicles. (See Sectin f these guidelines: NZTA Cmpliance.) Persnal prtective equipment (PPE) Wearing PPE apprpriate fr the task reduces expsure t, r cntact with, the hazard. Fr example: wear hearing prtectin fr wrk in nisy areas. Other PPE suitable fr wrking with precast cncrete may include steel-ted bts, glves, safety glasses, helmets and high-vis vests. Page 29

30 PCBUs must prvide any PPE needed t carry ut wrk, and ensure wrkers knw hw t wear it, use it, and care fr it. PPE is the least effective type f cntrl and shuld nt be the first r nly cntrl measure cnsidered. 3.4 CHECK: MONITOR PERFORMANCE OF CONTROL MEASURES Cntrl measures shuld remain effective, be fit fr purpse, be suitable fr the nature and duratin f the wrk, and be used crrectly by wrkers. Mnitr the perfrmance f cntrl measures t check if they are effective. Encurage apprpriate reprting. Make it easy fr wrkers t reprt incidents, near misses, r health and safety cncerns. 3.5 ACT: TAKE ACTION ON LESSONS LEARNT The PCBU shuld regularly review the effectiveness f cntrl measures (eg thrugh wrkplace inspectins). This is likely t invlve engaging ften with wrkers and their representatives t check if the cntrl measures are eliminating/minimising wrk risks. All plicies, prcesses and systems shuld have a scheduled date fr a review/audit prcess t check that they re being fllwed and are still fit fr purpse. The PCBU shuld investigate incidents and near misses t identify their causes and what needs t change t prevent them frm happening again. The PCBU can use the results f nging wrker cnversatins, reviews/audits, investigatins and any wrkplace/wrker health mnitring t cntinually imprve the effectiveness f cntrl measures. If prblems are fund, g back thrugh the risk management steps, review the infrmatin and make further decisins abut cntrl measures. 3.6 HEALTH AND SAFETY BY DESIGN Health and Safety by Design is the prcess f applying risk management methds during design t eliminate r minimise risk fr wrkers and thers. The aim is t cntinually imprve the management f risk by prviding wrkers with the highest level f prtectin against harm t their health, safety and welfare, s far as is reasnably practicable. Hw is Health and Safety by Design applied? The way Health and Safety by Design is applied will vary depending n the nature f the design r wrk system and its intended use. The key principles underpinning the apprach are: A capable, multidisciplinary team with a mix f knwledge, skills, expertise and experience, and team members wh cnsult, c-perate and c-rdinate with each ther. Page 30

31 A life-cycle apprach chsing inherently safer and healthier ptins at every stage - frm the initial cncept design thrugh t decmmissining and dispsal. Cnsider csts and benefits. A systematic risk management apprach t identify, assess and manage risk. Apply the hierarchy f cntrls, if apprpriate, fcusing first n eliminating risk. Gd dcumentatin, cmmunicatin and infrmatin transfer. Frequent mnitring and review, allwing fr change if needed. EXAMPLE Critical cnsideratins fr Health and Safety by Design fr precast cncrete may include but are nt limited t: - stability and strength f precast cncrete elements during manufacture, erectin and supprt f temprary wrks - precast channels/ducting (penetratins) fr services s that wrkers dn t have t cut channels r hles in cncrete later; this helps wrkers t avid creating silica dust and nise - cast-in cmpnents designed-in s that wrkers dn t have t drill them in later - the size f the crane/s and the space available t erect the elements - the ability t sequence the wrks and place the elements safely. Fr mre infrmatin WrkSafe s quick guide Identifying, Assessing and Managing Wrk Risks WrkSafe s interpretive guidelines General Risk and Wrkplace Management, Part 1 See Sectin 4: Using PPE t manage risk WrkSafe s fact sheet Reasnably Practicable WrkSafe s gd practice guidelines Health and Safety by Design [due mid-2018] Page 31

32 SECTION 4: WORKER TRAINING Training helps peple wrking with precast cncrete t gain the skills and knwledge they need t wrk safely. PCBUs must ensure, s far as is reasnably practicable, all persns (wrkers and thers) are prvided with any infrmatin, supervisin, training and instructin needed t prtect them frm wrk-related health and safety risks. 4.1 WHAT COULD GO WRONG? WHAT COULD GO WRONG? Injuries, ill-health r death result frm the actins f: untrained r prly trained wrkers inexperienced wrkers that are nt apprpriately supervised. POSSIBLE CAUSES Wrkers are nt adequately trained t carry ut wrk tasks (eg the training and/r inductin prcess des nt cver all the infrmatin wrkers need t knw, such as hazards n site, cntrl measures, PPE use). The training is nt understd by the wrker perhaps it was nt adapted t suit the wrker s numeracy (number), literacy (reading/writing) r language skills. Wrkers have nt undergne regular refresher training resulting in declining r ut-f-date skills. Inexperienced wrkers are nt adequately supervised (eg the supervisr is t far away frm the wrker they are supervising that is, nt within reach, r visual cntact). Sectin 36 f HSWA cvers the primary duty f care. 4.2 TRAINING Training ensures that each persn - and the team as a whle - can perate safely. Training includes prviding infrmatin r instructin. Page 32

33 PCBUs must: make sure that wrkers have the apprpriate experience and training needed fr precast cncrete wrk engage with wrkers when making decisins abut prviding infrmatin and training. Prvide nging training as needed, including refresher training s that skills and knwledge are kept up-t-date. Skills decline if they are nt used regularly. Training shuld be carried ut by a cmpetent persn r apprved training rganisatin. Cnsider inviting experienced wrkers wh understand the risks invlved in the wrk t assist with training. Wrk with precast cncrete that may require higher levels f infrmatin, training, instructin r supervisin includes: handling and lifting transprting bracing and prpping erectin and installatin CUSTOMISE TRAINING Training shuld be custmised and fit fr purpse. Use the prmpts belw when planning what training t ffer and hw and where t prvide it. Adequate time shuld be allwed fr training t take place. PLANNING TRAINING: WHAT TO CHECK When and where will training take place? Will training be carried ut internally r externally, and wh will deliver it? What experience and cmpetencies d trainers r supervisrs need? Hw will trainers tailr training t take int accunt wrkers language skills, including their reading and writing skills and their ability t wrk with numbers? Wh will supervise wrkers receiving n-the-jb training? Will training be paper-based, audi-visual, r cmputer-based (including n a tablet r smartphne)? Are there relevant frmal qualificatins wrkers can btain? Will training cver identificatin f hazards related t: using plant and equipment? Page 33

34 PLANNING TRAINING: WHAT TO CHECK (cntinued) handling, transprting, string, and erecting precast cncrete? wrking at height? Will training cver selecting, fitting, caring fr, using and string the required PPE and equipment? Hw will wrkers demnstrate understanding? Hw will daily reminders f safe wrk practices be prvided after training (eg standard perating prcedures [SOPs], psters r flash cards summarising the key pints)? Will new and/r inexperienced wrkers be trained thrughly fr all tasks they may need t carry ut, r will training happen n a task-by-task basis as needed? Fr mre infrmatin WrkSafe s fact sheet Prviding Infrmatin, Training, Instructin r Supervisin fr Wrkers WrkSafe s gd practice guidelines Writing fr Health and Safety WORKER COMPETENCE Always assess the cmpetence f any new wrker n site. As a starting pint, cnsider: What is the wrker s level and depth f experience carrying ut the tasks required t wrk with precast cncrete? What industry-specific training and/r qualificatins des the wrker already have? Is the wrker able t identify the cmmn hazards f precast cncrete wrk and use effective cntrl measures t manage the risks? Is the wrker familiar with: cmmn health and safety terms and practices? industry-specific terms and practices? Des the wrker have the physical skills needed t carry ut the tasks required? Answers t these questins will help with decisins abut what training and supervisin new wrkers need. Page 34

35 Next cnsider: What is the wrker being asked t d? What machinery, equipment and substances will the wrker need t use? Des the wrker have difficulty reading? If s, hw else will yu share the infrmatin they need t knw? Is the first r preferred language f the wrker a language ther than English? OTHER FACTORS AFFECTING WORKER COMPETENCE Even if wrkers are well-trained ther factrs can affect a wrker s cmpetence. Fr example, a lack f sleep, pr diet, relatinship prblems, mney prblems, alchl and drug abuse, health prblems and uncertainty abut the cntinuity f wrk can all affect peple s ability t wrk safely. Wrk shuld be well-planned and scheduled t avid undue pressure n wrkers. Allw enugh time fr wrk-flw changes due t unexpected events such as machinery breakdwns r adverse weather. If wrkers are expsed t extreme temperatures r physical demands, cnsider if jbs can be rtated t minimise the effects. 4.4 INDUSTRY QUALIFICATIONS One way f demnstrating cmpetence is thrugh natinally recgnised qualificatins, r cmpnents f them. Fr further infrmatin n cncrete-related training and qualificatins, cntact the Building and Cnstructin Industry Training Organisatin (BCITO). BCITO is appinted by the gvernment t develp industry qualificatins and set standards fr the New Zealand building and cnstructin sectr. NZQA s Natinal Certificates and Natinal Diplmas recgnise skills and knwledge that meet natinally endrsed unit and achievement standards. EXAMPLE The Natinal Certificate in Precast Cncrete (Level 3) is designed fr peple wanting t wrk as precast cncrete manufacturers, as well as prviding a way t recgnise the current cmpetence f peple already wrking in the cncrete industry. Fr mre infrmatin Page 35

36 4.5 TRAINING RECORDS WrkSafe recmmends that PCBUs keep training recrds. Assess and recrd the level f training wrkers have achieved. Recrds culd include cpies f external training prvider certificates, in-huse r n-the-jb training recrds and attendance lists. NZQA requires rganisatins awarding a qualificatin t keep recrds f learner prgress and prgramme cmpletin, and the date the qualificatin was awarded and certificate issued. 4.6 RESPONSIBILITIES WHEN WORKING WITH TRAINEES A trainee wrker can be invlved in precast cncrete wrk as lng as they are directly supervised. What is direct supervisin? In these guidelines, direct supervisin means within reach, r within visual cntact. The supervisr is respnsible fr mnitring the wrk and ensuring cmpliance with regulatins and recmmended practice. They must be in a psitin t take immediate charge in an emergency. The apprpriate rati f experienced wrkers t trainee wrkers depends n the level f experience and cmpetence f each trainee, the cmplexity f the precast cncrete wrk being undertaken, and the risks assciated with any mistakes that trainees may make. Fr mre infrmatin WrkSafe s interpretive guidelines General Risk and Wrkplace Management (Part 1) See Sectin 3: Infrmatin, training, instructin and supervisin WrkSafe s special guide Intrductin t the Health and Safety at Wrk Act 2015 WrkSafe s fact sheet Prviding Infrmatin, Training, Instructin r Supervisin fr Wrkers Page 36

37 SECTION 5: SITE MANAGEMENT Precast cncrete wrk usually takes place as part f a larger prject. PCBUs must wrk tgether with ther PCBUs and wrkers t cntrl wrk-related risks. The PCBU respnsible fr the site typically assigns smene t be the site manager. Site management includes respnsibilities such as ensuring that the required PPE, equipment and facilities are in place, as well as handling site-specific issues such as traffic management. 5.1 SAFE SYSTEM OF WORK A safe system f wrk means the steps a PCBU takes t eliminate r minimise wrk risks, s far as is reasnably practicable. Put a safe system f wrk in place befre wrk starts. This ensures the wrk happens in the right lcatin with the right plant and equipment n site and with the right wrkers with relevant cmpetencies. The PCBU must engage with wrkers carrying ut the wrk and their representatives when develping the safe system f wrk. All PCBUs must cnsult, c-perate and c-rdinate with ther PCBUs wrking tgether at the same lcatin r thrugh a cntracting chain, s far as is reasnably practicable. A safe system f wrk shuld include: assigning respnsibilities cmpleting a Jb Safety Analysis (JSA) t dcument chsen cntrl measures see Appendix E fr a template cnsulting a cmpetent persn regarding any temprary wrks design identifying health and safety hazards and risks describing hw any identified risks will be cntrlled, including prcedures fr unexpected events such as bracing failure describing hw cntrl measures will be implemented, mnitred and reviewed effective cmmunicatin systems (s that wrkers can regularly cnfirm that they are safe) incident investigatin and reprting methds an emergency plan and prcedures. Page 37

38 Engage with all wrkers abut any prpsed changes t the safe system f wrk. Every safe system f wrk needs regular reviews. The review prcess shuld take int accunt matters such as: advances in technlgy incident reprts any new hazards r risks identified new industry guidelines r new legislatin effectiveness f cntrl measures mnitring f the wrk envirnment mnitring f wrker health. Fr mre infrmatin WrkSafe s fact sheet Reasnably Practicable SITE ASSESSMENT BEFORE WORK BEGINS Carry ut a site assessment befre wrk begins. (See related cntent in these guidelines, as indicated.) INITIAL SITE ASSESSMENT: WHAT TO CHECK SITE CONDITIONS (See als Sectin 10) What is the nature and cnditin f the grund, surface r structure n which the precast cncrete element will be erected? WORKER FACILITIES (See als 2.1.1) Are there adequate facilities fr wrkers welfare (eg drinking water, tilets, and break facilities)? If nt, what will be put in place? ENVIRONMENTAL CONDITIONS Will the element/s be subject t envirnmental lads such as earthquakes, wind, vehicle impact, r snw? (See als Appendix H) What weather cnditins are expected during the prject (eg seasnal changes)? (See als 10.1) SITE ACCESS, SAFETY AND SECURITY (See als 9.5.5; 10.8) Hw will wrkers access the site? Page 38

39 Is pedestrian access thrugh the site required? IF YES: Hw will this be managed? Hw will vehicles access the site? Is a site-specific traffic management plan required? Will persns ther than wrkers have access t the site? If s, hw will these persns be prtected frm health and safety risks arising frm the wrk? Is there a need t set up: exclusin znes (defined areas where peple are nt allwed t g when particular wrk is being dne)? cvered walkways? barriers r fencing t islate peple? Hw will the site be prtected frm unauthrised access? STORAGE (See als 9.4) Is there a secure and prtected lcatin fr strage? Is there enugh space t stre elements? Is there enugh space t stre ther materials needed n-site? Is there enugh space t stre equipment? Hw will wrkers and vehicles access the strage area/s? SERVICES (See als 10.1; ) Are service mark-uts shwn in plans r ther infrmatin, fr example, shwing the lcatin f verhead and undergrund services? Are there electrical cnductrs r cables nearby? IF YES: Culd wrkers cme int cntact with the cnductrs r cables at any stage fr example, during delivery t the site, erectin, r ther wrk activities? Page 39

40 PERMITS, CONSENTS AND NOTIFICATIONS (See als Appendix F) Are there lcal authrity requirements? Are ther permits r cnsents required? Des the wrk need t be ntified t WrkSafe? Shuld anyne else be ntified? Fr example, ther PCBUs at site, neighburs, the airprt if a crane bm will affect flight paths. SITE-SPECIFIC DOCUMENTATION (See als Sectin 7) What site-specific dcumentatin is required, including (but nt limited t): a health and safety plicy? a summary f the wrkplace safety plan? an emergency plan? (See Sectin 5.3 f these guidelines.) a wrkplace safety inductin card? a visitr and wrkplace inductin register? an accident/incident register, including near misses? injury/ill-health/incident reprting? hazard identificatin? risk assessments? safe/standard perating prcedures? drawings (eg shp drawings, cntract drawings, structural drawings)? OTHER PCBUs ON SITE (See als 2.1.2) What ther PCBUs will be n site? Hw will the PCBUs - s far as is reasnably practicable - cnsult, c-perate and c-rdinate activities with ther PCBUs (eg t manage risks frm shared activities)? What ptential risks may arise frm ther wrk being carried ut n site? Page 40

41 5.3 EMERGENCY PLAN The PCBU must have an emergency plan fr the wrkplace cvering any likely type f emergency. Emergency plans shuld be develped with wrkers: the PCBU must engage with wrkers n health and safety matters that affect them. T remain effective, the plan needs t be maintained, regularly tested, and imprved (if and when required). Wrkers shuld be trained in the emergency plan. The plan shuld be available and accessible t the peple wh need it. T ensure a c-rdinated respnse t an emergency, the emergency plan shuld be included within any brader cnstructin prject emergency plan, and be cmmunicated t all wrkers. Identify all ptential emergency cnditins and develp a suitable respnse fr each ne. Sites shuld be vacated: after a majr accident event after a ntifiable incident after a severe weather event after an earthquake. EMERGENCY PLAN: WHAT TO CHECK Des the emergency plan identify: what t d in an emergency? rles and respnsibilities (eg f managers, wardens)? wh is trained t administer first aid? where first aid and medical prvisins are? where the nearest emergency centre is? the lcatin f alarms? the lcatin f fire extinguishers? escape rutes? assembly pints? lcatin f emergency supplies? up-t-date lists with emergency cntact details (eg phne numbers fr staff, emergency services, clients, suppliers and yur insurance cmpany)? Page 41

42 Fr mre infrmatin WrkSafe s quick guide Electrical Safety n Small Cnstructin Sites WrkSafe s interpretive guidelines General Risk and Wrkplace Management, Part 1 See Sectin 3: Infrmatin, training, instructin and supervisin WrkSafe s special guide Intrductin t the Health and Safety at Wrk Act 2015 WrkSafe s quick guide Identifying, assessing and managing wrk risks WrkSafe s fact sheet Prviding infrmatin, training, instructin r supervisin fr wrkers Page 42

43 SECTION 6: DESIGN Make sure that all design phases take health and safety int accunt. A PCBU wh designs plant, substances r structures has additinal health and safety duties under HSWA. Sectin 39 f HSWA specifies the duty f a PCBU (a designer) wh designs plant, substances, r structures PCBUs wh are designers must, s far as is reasnably practicable, make sure that the plant, substances, and structures they design are withut health and safety risks when they are used fr their intended purpse in a wrkplace. The designer must carry ut r arrange the carrying ut f any calculatins, analysis, tests r examinatins needed t make sure the plant, substance r structure designed, manufactured r supplied is withut health and safety risks, s far as is reasnably practicable. The designer must share this and ther infrmatin with each persn wh is prvided with the design. See Appendix G f these guidelines: Duties f designers, manufacturers, imprters, suppliers, installers, cnstructrs and cmmissiners. A cmpetent persn shuld prvide written site-specific verificatin cnfirming that design requirements have been cmplied with. 6.1 DESIGNERS Within these guidelines a designer is a cmpetent persn, such as an engineer with experience in such matters, engaged t carry ut ne r mre stages f design. S far as is reasnably practicable, the design ensures that precast cncrete and supprting structures are able t resist any reasnably freseeable static, dynamic and impact lads, taking int accunt the required factrs f safety. When stages f design are undertaken by individual designers, each designer has respnsibility fr the stage ver which they have cntrl. In these circumstances, the designers must cnsult with each ther n the health and safety implicatins f the design. In precast cncrete wrk this includes, but is nt limited t, the structural designer, as well as ther peple respnsible fr erectin design and temprary wrks. Fr example: designer/s f a system that prvides safe temprary supprt f precast cncrete until it is fully supprted by the cmpleted wrks Page 43

44 designer/s wh cntribute t the develpment f a safe system f wrk fr the erectin f precast r tilt panel cncrete. Designers are in a strng psitin t help create healthy and safe wrkplaces. Eliminating r minimising risks in the design stage is an effective way f prviding the best prtectin. WrkSafe recmmends using a Health and Safety by Design prcess, utlined in Sectin 3.6 f these guidelines. This prcess applies risk management methds and allws early identificatin f risks that can be addressed thrugh design. Fr example, designing channels r ducting fr services befre they are manufactured means that wrkers avid expsure t the silica dust and nise created when cncrete is cut t add channels fr electricity r ther services. 6.2 DESIGN PHASES Precast cncrete design can be divided int three distinct design phases: Structural design fr the in-service perfrmance f a precast cncrete element as part f the cmplete structure. The structural designer is usually engaged by the client. They are smetimes knwn as the prject design engineer r in-service designer. The structural designer: prduces the structural design, and issues the structural drawings may recmmend design lads fr temprary wrks designs and specifies any permanent structural cnnectins (eg cnnectins t the permanent structure) reviews the shp drawings apprves stability f the structure during cnstructin (when requested), particularly befre remving temprary supprts. Design f the manufacturing and transprt prcess, including design f: layut f the precast prductin facility precast beds access t and prtectin f the beds and mulds mulds demulding handling, strage, and transprt f the precast elements craneage Page 44

45 Design f the site fflading and erectin prcess, including design f: access lifting strage erectin and temprary supprt f the precast elements, cnsidering the lads impsed. The head cntractr typically ensures that ne r mre cmpetent persns are engaged t check that aspects f handling and placing f precast cncrete have been cnsidered. Fr example, the cmpetent persn respnsible fr erectin design shuld: liaise with the head cntractr, precast manufacturer and erectr t agree n the erectin prcedure and sequence undertake erectin design t ensure the precast cncrete can resist freseeable issues with handling, transprt, erectin, envirnmental, and cnstructin lads prvide the precast manufacturer with infrmatin shwing the necessary lifting and insert lcatins, rientatins and specificatins (including any additinal reinfrcement/strngbacks) required prduce rigging cnfiguratin, erectin sequence and drawings (including brace specificatins) review the cmpleted shp drawings issue a certificate cnfirming erectin design cmplies with relevant cdes. PRECAST CONCRETE DESIGN: WHAT TO CHECK Des the precast cncrete design cver: determinatin and specificatin f the size and shape f the precast cncrete element/s? additinal reinfrcement (where required)? strngbacks (where required)? brace fundatins, in-grund mass blcks, ftings and ther fundatins (where required)? lads, including: the effect f suctin and adhesin at separatin frm the frmwrk r casting bed (lift ff)? dynamic and impact lading during transprtatin, where applicable? erectin and bracing lads? cnstructin lads, including any backfill and surcharge lads? permanent, impsed and ther lads n the element and any temprary supprt r bracing system, in accrdance with apprpriate sectins f the AS/NZS 1170 series (seismic, wind and snw)? Page 45

46 ERECTION DESIGN: WHAT TO CHECK Has erectin design addressed: the size and shape f the precast cncrete elements? erectin lads? design f the supprting members t cater fr the erectin lads? lifting inserts? cast-in cmpnents (such as cnnectrs)? gruting requirements? requirements fr additinal reinfrcement? fundatins t brace any vertical precast cncrete elements during cnstructin? dimensined lcatins f braces r prps and their cast-in cmpnents? the size and type f cast-in cmpnents t be used fr brace r prp cnnectins? minimum dimensins f drilled piles r in-grund mass blcks (if used)? These shuld allw fr the spacing and edge distance requirements fr the number and type f cast-in cmpnents being used. base restraint details t be incrprated? (Where frictin alne will nt prvide base restraint with an apprpriate safety factr.) GENERAL CONSIDERATIONS All aspects f design shuld be carried ut in accrdance with any relevant legislatin. If the temprary supprt system f precast cncrete will be in place fr six mnths r less, the design f that system shall be based n: 1 in 100 years annual prbability f exceedance fr ultimate limit states fr wind and seismic lads, and 1 in 50 years fr snw lads. Design fr the serviceability limit state shall be based n a 1 in 25 years event. Cmpetent persns shuld design the handling, transprt, erectin and temprary supprt systems fr precast cncrete. Allwance is t be made fr all reasnably freseeable lad cnditins including but nt limited t the cnditins utlined in Sectin B1.3.3 f Schedule 1 f the Building Cde. (See Appendix H f these guidelines.) Page 46

47 6.3 TEMPORARY WORKS AND FALSEWORK Within these guidelines: temprary wrks means temprary facilities (such as fencing, site ffices and wrkers facilities), and bjects such as scafflding, safety barriers and falsewrk, that are required n site nly until the permanent wrks are cmpleted. falsewrk means the temprary structures and/r systems used t supprt a permanent structure during erectin and until it becmes self-supprting. Temprary wrks and falsewrk may include prpping systems, bracing systems, frames, scafflding, backprpping, beams, bearers and ties, and smetimes prprietary systems and specifically engineered systems. Typical elements fr falsewrk supprting precast cncrete may include wall panels, beams, clumns, flrs and rfs (fr example, when cnstructing buildings, bridges, stadiums and reservirs). Temprary wrks shuld be designed t supprt lads impsed by the precast cncrete elements alng with envirnmental and ther impsed lads. The structural designer shuld specify wind and seismic design lads. This is particularly imprtant fr multi-strey wrk where the derivatin f the lads is cmplex and needs t take int accunt many influencing factrs. Lads are transmitted thrugh the falsewrk t the supprting structure r t the grund. Backprpping may be required t distribute the lads thrugh a partially cmpleted structure and is typically applied t multi-strey cnstructin. Fr flring systems and certain prprietary prducts, the structural designer shuld prvide sufficient infrmatin fr the design t be undertaken, including the applied lads and the expected perfrmance f the precast elements (such as deflectins and vibratin). The structural designer shuld als prvide infrmatin abut the grund cnditins and the effect any temprary supprt systems may have n them. Falsewrk is t be designed by cmpetent persns wh calculate the impsed lads, determine an apprpriate slutin, check stability and settlement, and prvide dcumented infrmatin fr the erectin, maintenance and dismantling f the falsewrk. Infrmatin shuld include: design lads dimensinal set ut falsewrk cmpnentry (with manufacturer s details where applicable) erectin sequencing criteria fr remval remval prcedure. Page 47

48 6.3.1 DESIGN TO RESIST LOADS Where the falsewrk affects lading t the cmpleted structure, the structural designer shuld be cnsulted. Falsewrk and temprary wrks shuld be designed t resist all reasnably freseeable lads, including: cnstructin lads differential settlement wind lads fr temprary structures in accrdance with AS/NZS seismic lads fr temprary structures in accrdance with AS/NZS Falsewrk shuld be fixed t a slid, flat cncrete surface r anther surface capable f resisting the applied lads. Falsewrk fundatins are nrmally flr slabs, ftings, r mass blcks (als knwn as deadmen). Falsewrk and fixings shuld be designed t ensure the verall system can supprt the applied lads. A cmpetent persn shuld sign ff the design prir t erectin TEMPORARY SUPPORT FOUNDATIONS All fundatins shuld be designed t prvide full supprt t the lads impsed n them by the falsewrk. An in-grund r n-grund mass blck made f cncrete is ne methd fr transferring lateral lads t the grund in cnditins where flr slabs are nt available t resist the brace lads. The mass blck is specifically designed t supprt brace lads. Lateral lads are resisted by the mass f the cncrete blck and the frictin between the cncrete surface and the supprting grund. Mass blcks shuld be designed by cmpetent persns wh take int accunt the varius design lads and cnditins utlined in Sectin f these guidelines. Brace lads can act in tensin and cmpressin. The resultant frces n the mass blck may reduce the base frictin. This needs t be cnsidered in the design. If piles r mass blcks are used as brace fundatins, they shuld be designed t ensure the lads can be safely transferred t the sil. The dimensins are designed t allw fr the cnnectin f all anchr pints and apprpriate edge distances. Other engineered systems, such as screw anchrs, are available. Any prprietary system has t be designed t ensure the lads can be safely transferred t the sil. 6.4 SIZE AND SHAPE OF ELEMENTS When deciding the size and shape f precast cncrete elements, designers shuld take int accunt: manufacturing restrictins Page 48

49 crane safety (see als Sectin 10.6 f these guidelines), cnsidering: the size and capacity f crane(s) required fr lifting and erectin psitining f a tailing crane n site (if tailing crane required t transprt a large panel) the effect f the panel size n lifting restrictins such as wind speed and the rating f the cranes available a large panel may lean twards the crane and its peratr when placing; a smaller panel may allw the crane t reach further, allwing the crane peratr t be clear f the lift wind rating; this can be calculated by a cmpetent persn, r by using the crane manufacturer s recmmended calculatin fr a specific crane site lcatin and envirnment (eg site access; lcatin and prximity f pwer lines) requirements fr temprary supprt systems transprt restrictins. 6.5 DESIGN OF THE MANUFACTURING, TRANSPORT AND ERECTION PROCESSES Designers shuld cnsider all reasnably freseeable lads impsed n the precast cncrete element during all stages frm manufacturing f the element thrugh t its final psitin in the cmpleted structure. As the lads can differ during varius stages, the structural designer shuld cnsider whether precast cncrete elements culd buckle r becme unstable. The design shuld cnsider all reasnably freseeable physical cnditins likely t be experienced during each phase f the prcess, such as: variatins in lad distributin (with time) variatins in prpping lads due t the effect f pre-stressing lading n bracing inserts, lifting inserts, lifting gear and precast cncrete frm the dead lad, the sling angles, and any dynamic lad r impact lad applied thrugh handling lifting requirements, based n the type f lifting appliance (eg mbile crane, crawler crane, truck lader crane (Hiab), pick and carry crane, gantry crane, r digger) wind lading n large precast surface areas sme elements may nt be able t be lifted until the wind speed reduces. There shuld be sufficient temprary base restraint t prevent a sliding failure (kickut) at the base r supprt f the precast cncrete element. Nte that the panel weight may nt prvide base restraint. Page 49

50 6.5.1 RIGGING DESIGN The design shuld ensure that the precast cncrete element and assciated rigging is capable f supprting the lads at all stages f the lift. Fr elements underging rtatin during the lifting peratin, all cnditins listed abve shuld be taken int accunt. The designers need t shw the rigging systems that they tk int cnsideratin. A cmpetent persn makes sure that the rigging is set up as designed. Lads n lifting inserts and stresses within precast cncrete vary with changes t the rigging. When the design requires a particular sling length r lifting system, the designer shuld cmmunicate that infrmatin t the rigger r the lifting supervisr. See Sectin 10.9 f these guidelines fr infrmatin abut rigging practices and cnfiguratins CONCRETE WEIGHT AND STRENGTH Cncrete strength increases ver time and is affected by curing cnditins, envirnment and temperature. Cnsider the cncrete strength required fr each stage, including: lifting frm mulds destressing factry handling transprt site handling temprary fixing. Refer t the NZS 3112 series (Methds f test fr cncrete) as needed. Fr example, NZS cvers methds f sampling fresh cncrete and methds f test fr unit mass, wrkability, cnsistency, bleeding, air cntent and setting time f fresh cncrete. The structural designer will prvide the cncrete strength required fr a precast cncrete element t meet the requirements f the building, based n strength r durability requirements. Cncrete needs t be at sufficient strength t fulfil its purpse. The minimum cncrete strength at remval frm the muld, rather than the minimum number r days, shuld be specified. T achieve the cncrete strength required at the time f lifting, precast cncrete elements may be manufactured with a cncrete strength higher than specified n the shp drawings. The required cncrete strength f the precast element shuld be nted n the shp drawings. Althugh using cncrete f a higher strength than the structural designer specified des nt nrmally have a negative impact n the structure, in sme cases it can adversely affect the verall perfrmance by changing the lad distributin. If higher strength cncrete is needed t achieve the capacity f the lifting r bracing inserts, the structural designer shuld apprve the change. Page 50

51 With apprval frm the structural designer, higher strength cncrete can be used: t allw early remval frm mulds t meet handling requirements t accmmdate cnstructin lads. Sme lifting inserts may nt be able t take their full lad if they are nt embedded deeply enugh r the cncrete is nt strng enugh when the element is being lifted. Greater cncrete strength may be needed t safely handle the element. The precast manufacturer and the structural designer may help reduce the weight f individual precast cncrete elements by altering the size, varying the cncrete density, r using ther apprpriate design prcedures. If an element is t be erected, the head cntractr and the erectr shuld be given the fllwing infrmatin befre erectin: the element s weight the element s centre f gravity any special handling requirements (eg if lad equalising measures r strngbacks are required) MINIMUM STRENGTH FOR LIFTING FROM MOULDS The minimum cncrete strength fr lifting elements frm mulds needs t allw the lifting inserts t develp sufficient strength and the element t have sufficient bending strength. The cncrete element needs t reach the minimum required cncrete strength fr lifting and erectin. Calculate the minimum cncrete strength needed t lift the elements frm the muld using: cncrete stresses at the lifting pints stresses caused by the transfer f pre-stressing frces r handling. Take int accunt that: the flexural stresses may nt determine minimum cncrete strengths fr vertically cast cncrete elements, r elements cast n tilting mulds transprt ver rugh grund may cause impact lads FRICTION AND SUCTION LOADS Suctin lads ccur when precast cncrete is being lifted ff the casting bed r stacks, adding direct lading t crane lifting equipment and lifting inserts. Frictin r suctin t the muld can increase the frce required t lift r release an element frm the muld. Suctin lads can cause lifting equipment failure, structural crane damage r crane instability (in the case f mbile cranes). Suctin lads can als damage Page 51

52 precast cncrete elements. Nte that suctin lads are based n the surface area rather than the panel weight. Designers shuld cnsider the effects f suctin lads t ensure safety and the integrity f the precast elements. Factrs that increase suctin include: failing t use an effective release agent (bnd breaker) failing t apply the release agent effectively by missing sme parts f the bed r by applying inadequate amunts f release agent failing t allw fr a prfiled r textured surface in the design. Make sure that frictin r suctin lads d nt verlad lifting devices r inserts, r exceed the cncrete strength at the time f lifting. Bth frictin and suctin can be reduced by applying a suitable, high quality muld release agent. T reduce frictin, muld sides shuld be detailed with adequate draw, r be released t allw them t spring back. Suctin n flat muld surfaces is increased by the presence f water. Suctin pressure can be relieved by lifting gently at ne end r edge f the element. If excessive frce is used fr initial release frm the muld, the sudden release f strain energy may cause high impact lads and unpredictable sudden mvements. Take particular care if the lifting frce applied exceeds the weight f the precast element by mre than 10% DYNAMIC/IMPACT LOADS Precast elements are subject t dynamic lads during handling and transprtatin. The dynamic influence increases the lad n the lifting inserts, clutches, cncrete and rigging as well as n the crane. The dynamic influence has t be incrprated in the design by multiplying the lad impsed by the dynamic factr. The magnitude f the dynamic factr depends n the lifting equipment and the grund cnditin. The designer shuld cnsider the dynamic factrs shwn in the fllwing table, alng with ther general cnsideratins f design (that is, the factr f safety fr the cnstructin f cncrete elements, the factr f safety fr lifting inserts, and the factr f safety fr the lifting system). Means f transprtatin A statinary crane, including an verhead gantry crane, a crane standing n utriggers r a twer crane Dynamic factr will be a minimum f: 1.2 Mbile lifting device travelling n an even, prepared surface 2.0 Mbile lifting device (such as a digger, back he r pick and carry crane) n an uneven surface 5.0 Table 2: Dynamic factrs based n means f transprtatin Page 52

53 6.5.6 REPETITIVE LIFTING Lifting inserts in elements that will be lifted multiple times during their service life shuld be designed using a minimum safety factr f 5.0. Fr example, the lifting inserts in cncrete barriers, service lids and crane cunterweights shuld stand up t repetitive lifting ADDITIONAL REINFORCEMENT The design shuld specify any additinal reinfrcement required t accmmdate frces during handling, transprt and erectin. Additinal reinfrcement may be used: at temprary supprt pints where stresses are greater than thse the final structure was designed fr fr handling elements that dn t achieve their full strength until built in (eg partial-height precast beams) near the base f precast cncrete elements where necessary t resist lad cncentratins frm levelling shims r ther temprary supprts at the edges and arund penings in the element t resist thermal and shrinkage stresses and prevent cracking resulting frm handling elements when there is a chance f lad reversal resulting frm handling during transprt r erectin. During handling and transprtatin, cncrete elements can be subject t stresses that exceed the design stresses caused by the final lading f the element. There is a chance f unintentinal verlading and elements being damaged. The erectin design shuld incrprate the effect f the lifting lads n the structural integrity f the cncrete element. If required, additinal reinfrcement r strngbacks (see Sectin f these guidelines) shuld be added t strengthen the element. Cncrete elements may be at risk f buckling if the vehicle transprting them tilts n a curved rad surface. They can als buckle and becme unstable during lifting and erectin. A designer shuld cnsider the placement f lifting inserts, the use f strngbacks and spreaders, r the use f additinal reinfrcing t ensure that cmpressin flange buckling (eg f a slender clumn) cannt ccur. This is particularly imprtant when sling angles cause cmpressin in the element and when lng thin elements have the ptential t rtate STRONGBACKS Strngbacks are temprary supprts used t: strengthen precast cncrete elements while being lifted supprt precast elements during cnstructin prevent ut-f-plane rtatin f dd-shaped cncrete elements. Page 53

54 Fr example, a strngback may be blted nt an element t allw it t be lifted safely withut cracking. Figure 4 shws strngbacks n a precast cncrete element. Figure 4: Strngbacks supprting a large precast cncrete element Large r awkwardly shaped precast elements may require the use f strngbacks t limit cncrete stresses t acceptable levels during handling. If the strngback itself is t be used as an attachment fr lifting, it shuld be specifically designed, certified and rated fr this purpse. Strngback cnnectins t the element shuld be by way f cast-in insert r structural expansin anchr. If structural expansin anchrs are used, the wrking lad shuld be less than the clamping frce prvided by the anchr. An engineer shuld cnsider the size, shape, weight and cnnectin details f elements when designing strngbacks. Strngbacks shuld be designed fr strength and/r fr deflectin, depending what is mst imprtant. They have t be stiff enugh t prevent the cncrete cracking due t differential deflectin. Strngbacks limit deflectin and prevent the cncrete exceeding its rupture strength and cracking when it is being lifted. Design shuld als take int accunt: any lifting gear attached t the precast element, and the methd f lifting the centre f gravity, t ensure that the element is lifted in the apprpriate psitin ut-f-plane lads during lifting and rtatin. When calculating the weight f an element and its centre f gravity fr lifting purpses, include the weight f the strngback/s. Page 54

55 Materials t be used fr the manufacture f strngbacks shuld be designed t a relevant standard such as NZS3404 and NZS3603. When an bject is hked nt a strngback it becmes a lifting beam and shuld then cmply with the requirements within WrkSafe s Apprved Cde f Practice fr Lad-Lifting Rigging. The design f lifting beams, spreaders and frames must be certified by a Chartered Prfessinal Engineer r Design Verifier apprved by the Ministry f Business, Innvatin and Emplyment as a Crane Design Verifier. A Design Verifier is emplyed by an inspectin bdy t carry ut the functins referred t in the PECPR Regulatins, and is the hlder f a relevant certificate f cmpetence. This means that all strngbacks with lifting pints used during the mvement f precast cncrete shuld be: designed, marked and tested by a CPEng r Design Verifier, and als thrughly examined by a cmpetent persn befre use (such as a qualified and experienced rigger wh can carry ut a lifting inspectin). A cmpetent persn shuld: certify strngback design and cnnectins t elements cnsider placement and type f the apprpriate insert when fixing strngbacks, fr example, cast-in inserts r trque-cntrlled expansin pstinstalled fixings apprve any changes t the specified strngback system befre the changes are carried ut. Strngbacks used fr lifting must be rated with a wrking lad limit. Fr mre infrmatin WrkSafe s Apprved Cde f Practice fr Lad-lifting Rigging. AS 4991 Lifting Devices LIFTING INSERTS Lifting inserts within a precast cncrete element shuld be specified as cast-in prducts. Lifting inserts shuld be prperly embedded in well-cmpacted uncracked cncrete t functin effectively. Every individual item f lifting equipment shuld be clearly and permanently marked with its WLL and a unique numbering system. This allws the item t be easily identified after the lifting inserts are cast int the element. Where cast-in inserts are unusable after casting, btain apprval frm a cmpetent persn (such as a rigger) t use an alternative rigging r fixing methd. Inserts r ther cmpnents that are fr permanent fixing in the cmpleted structure shuld nt be used as part f the erectin handling r lifting prcess unless apprval has been btained frm the structural designer. Page 55

56 The design f any cast-in cmpnentry fr cnnecting the precast cncrete element t rf framing and ther structural members shuld be in accrdance with the apprpriate New Zealand standard and the Building Cde. Use a minimum safety factr f 5 fr applicatins requiring repetitive lifting f a cncrete element during its service life. Fr example, cncrete rad barriers and manhle cvers are likely t be lifted multiple times. Lifting inserts that are used fr lifting and handling during all stages f manufacture, delivery and installatin shuld be designed t a minimum safety factr f 3. The applied lad needs t include the mass f the precast cncrete element as well as the influences frm suctin, dynamic impact lads, and rigging angles. Failure f lifting inserts and systems is a significant hazard and shuld be cnsidered during the design. As with lifting clutches, lifting inserts shuld be manufactured and tested in accrdance with a valid internatinal standard r technical reference (such as CEN TR Design and use f inserts fr lifting and handling f precast cncrete elements). The lad capacity and strength f lifting inserts is affected by many factrs. Develpment, prductin, testing, inspectin and applicatin f lifting inserts and lifting insert systems shuld meet acceptably high and cnsistent standards t ensure that they are fit fr purpse. WrkSafe recmmends that designers using prprietary lifting inserts in their designs ensure their design lads are within the supplier s recmmended lad limits. Factrs t cnsider include lad directin, cncrete strength at the time f lading, embedment depth, and edge distance. When chsing the number and size f lifting inserts t use, designers shuld refer t the list belw. It identifies the key factrs t cnsider. LIFTING INSERT DESIGN: WHAT TO CHECK Des lifting insert design include: the number, lcatin and placement f fixing inserts, adequate t resist the tensin and shear frces (static and cyclic) impsed n the cnnectins? reductin f insert capacity when placed near an edge r an pening? cmpnent reinfrcement? adequate cver t all inserts? ductile behaviur and rbustness f the insert? cncrete strength required t reach the required insert capacity? Have these factrs been cnsidered when selecting the number and size f lifting inserts required: lifting insert capacity? whether the element will be lifted repetitively ver its design life? ttal weight f the element? length and height f the element? Page 56

57 psitin f any cut-uts and penings? rigging arrangements? pssible influence f suctin and frictin during demulding? pssible influence f dynamic factrs when lifting n site with nn-statinary cranes? EDGE- OR FACE-LIFTING Design face-lifted cncrete elements that are t be fixed vertically t hang n mre than 10 degrees frm the vertical. If this isn t pssible, cnsider using edge-lifting r a cmbinatin f face-lifting and edge-lifting. Lifting inserts fr precast cncrete elements may be placed in the face r edges f the element. When the element will be tilted abut an edge using lifting inserts placed in the element face, the gemetric centre f the face-lift inserts needs t be abve the element s centre f gravity. Rated capacities f edge-lifters shuld be checked t ascertain the apprpriate rating. ADDITIONAL LIFTING INSERTS Additinal lifting inserts are ften added fr multiple lifts, fr demulding, handling, transprt, and erectin. When fixed length multi-legged slings are used fr lifting cncrete elements, any tw f the lifting inserts shuld be able t supprt the ttal lad. Avid multiples f three rws r clumns f lifting pints where equal lading is required, as cmplex rigging cnfiguratins are needed. Fr example, avid lifting arrangements invlving dd numbers f lifting pints. 6.6 IMPOSED ACTIONS Design fr site prcesses shuld cnsider any reasnably freseeable actins impsed n precast cncrete during handling, lifting, strage and temprary supprt. Cmpetent persns shuld cnsider the requirements fr strngbacks, spreaders, additinal reinfrcing r ther measures t avid buckling during erectin f the precast cncrete elements. Wind and seismic lads shuld be specified by the structural designer. These lads must be derived in accrdance with the relevant requirements in the AS/NZS 1170 series. Factrs cnsidered in the determinatin f these lads include (but are nt limited t): the terrain, height abve grund, wind directin, shielding, tpgraphy, shape f element, psitin n structure, surface rughness, site subsil classificatin, hazard factr, return perid, near fault factr and perid f vibratin. Page 57

58 Seismic assessment f precast elements n multi-strey structures requires a detailed structural analysis by a cmpetent persn. The design f the temprary supprt system shuld be in accrdance with the Parts and Cmpnents sectin f AS/NZS Fr mre infrmatin Building Regulatins 1992: Schedule 1: The Building Cde Relevant standards NZS 3101 Part 1 NZS 3101 Part 2 The Design f Cncrete Structures. Cmmentary n the Design f Cncrete Structures. AS/NZS 1170 Structural Design Actins set (individual Parts 0, 1, 2, 3 and 5 and assciated Supplements and Amendments). NZS 3104 NZS 3112 series Specificatin fr cncrete prductin. Methds f test fr cncrete. Page 58

59 SECTION 7: DOCUMENTATION Designers (as well as manufacturers, imprters, and suppliers) must prvide health and safety infrmatin abut their designs t ther PCBUs. All infrmatin shuld be clearly cmmunicated and timely. Dcumentatin relevant t precast cncrete wrk is likely t include cnstructin dcuments, shp drawings, erectin dcumentatin, permits, specificatins and detailed prject plans that cmmunicate the prcesses used t achieve the finished prduct. 7.1 ON-SITE DOCUMENTATION A cmpetent persn shuld prvide written site-specific verificatin cnfirming that design requirements have been cmplied with. The fllwing infrmatin shuld be available n-site: Drawings shwing the lcatin, dimensins, cncrete strength and reinfrcement f all in-grund mass blcks Verificatin that: all fundatins have been cnstructed in accrdance with the drawings the cncrete has reached the specified design strength allwable bearing pressures have been checked. 7.2 CONSTRUCTION DOCUMENTS Cnstructin dcuments: are issued by the client t the head cntractr, and by the head cntractr t the precast manufacturer may include specificatins and drawings fr the precast cncrete include dimensins, material prperties and fixing details specify design lads and perfrmance requirements fr precast elements that require additinal design by the manufacturer, such as hllw-cre flring. Page 59

60 7.3 SHOP DRAWINGS Shp drawings prvide all the infrmatin needed t manufacture the precast cncrete element. They: are used by the precast manufacturer t cnfirm details f manufacture t the head cntractr and client are used by the client t ensure their design has been accurately interpreted are used by the head cntractr t ensure dimensinal accuracy and all relevant cast-in items have been included shw hw prductin wrkers shuld prepare the muld fr each element define critical material aspects such as: cncrete grade and strength required at the time f lifting reinfrcing details specificatins fr the lifting pints penetratins surface finishes cast-in items the transfer strength required fr pre-stressing. are apprved by cmpetent persns representing the precast manufacturer, head cntractr, crane cntrller and client. Shp drawings may include: date and issue number prject name and lcatin identificatin and number f cncrete elements vlume and mass f cncrete elements cncrete element dimensins and centre f gravity cncrete design strength minimum cncrete strength required fr lifting. T achieve the strength required fr lifting, elements may need t be manufactured with strength grades higher than specified n the structural drawings. The structural designer shuld apprve these changes. type, size, cnfiguratin and lcatin f reinfrcement r strands type, size and cnfiguratin f any additinal reinfrcement required fr transprt and lifting make, type, size and lcatin f lifting inserts erectin layut. Page 60

61 There may be temprary wrks drawings cvering bracing, prpping, and arrangement f the elements in their final lcatin. The structural designer shuld check the shp drawings against the structural drawings fr cnsistency, and mark up any amendments. Amendments shuld be reviewed, signed and dated by the structural designer and returned t the precast manufacturer t incrprate int the manufacturing prcess/design. The apprved shp drawings shuld be marked fr cnstructin and kept n site by the head cntractr. 7.4 SITE OFFLOADING AND ERECTION INFORMATION Infrmatin abut site fflading and erectin can be included in ne r mre f the fllwing dcuments: dcuments describing the site access and craneage shp drawings the wrk prgramme (sequencing) dcuments describing the rigging and lifting; special lifts may include rtatin f precast elements and multiple crane lifts dcuments describing the temprary supprts, including prpping, back prpping, access and bracing dcuments describing the erectin prcesses and respnsibilities. 7.5 ERECTION DOCUMENTATION Precast elements shuld be erected accrding t a dcumented and planned sequence. Infrmatin required fr erectin shuld be prepared by a cmpetent persn with specific training and experience in erectin. The dcumentatin shuld include, where applicable, every aspect f the erectin prcess: scheduled dates eg fr delivery and erectin the lift plan bracing and prpping details fr each element: type and angle (as designed and certified by a cmpetent persn) cnfiguratin and size f erectin braces and, where applicable, knee braces and crss-bracing and any ther secndary bracing that may be required details f levelling shims; see Sectin 10.5 f these guidelines n-site lifting and handling requirements Page 61

62 any special requirements, such as: nn-standard finishes special lifting and handling prcedures preferred lifting and handling system t suit available equipment additinal reinfrcing fr handling, transprt r fr ther reasns all inserts and ther cmpnents t be cast-in fr lifting, handling r fixing type, make and lcatin f all required lifting inserts; if additinal reinfrcement r tensin bars are required fr the lifting insert t reach the full capacity, specify size, length and lcatin f the reinfrcement type, make, capacity and technical specificatins (as applicable) f: the rigging system lifting inserts bracing inserts and cast-in cmpnents, including type and capacity strngbacks (if required) size and grade f blts t be used fr any temprary erectin cast-in cmpnents rientatin (psitin relative t each ther) f the precast cncrete elements lcatin, rientatin and depth f inserts, and the size, cnfiguratin and cncrete cver f any cmpnent reinfrcement required. Details fr edge-lift inserts and ther inserts requiring reinfrcement shuld be btained frm the supplier. requirements fr erectin brace ftings (and prp ftings, if required), brace fixings, and cncrete strength f the brace ftings (including slabs) at the time f erectin site access, cnditins and limitatins, fr example: lcal street access grund cnditins access rads crane platfrms railway lines energy supply lcatins (eg pwer cables) verhead bstructins lcatin f any plumbing, electrical r cabling channels requirements fr gruting and lcatin f gruting ducts lateral restraint details transprt requirements (including any special prvisins). Page 62

63 7.6 PROJECT-SPECIFIC CHECKLISTS AND FORMS PCBUs may chse t use ther prject-specific checklists and frms, such as the examples described belw PANEL DESIGN During the design phase, sme PCBUs use a panel design checklist t specify details such as the lcatin f the pur, the rientatin f the panel, sling/rigging height, preferred strengthening methds (eg strngbacks) and the type f threaded inserts preferred. A sample panel design checklist is shwn in Appendix I f these guidelines LIFT DESIGN REQUEST Sme PCBUs use a lift design request frm t enable a lift design t be prduced. Althugh the precast manufacturer knws hw t lift and lad elements fr transprt frm their wn facility, requirements n a cnstructin site may differ. The frm requests details such as unit weight, preferred cmpressive strength at time f first lift, type and psitin f lifting inserts, rigging requirements (eg the number f cranes needed during installatin) and any design r certificatin requirements. See Appendix J f these guidelines fr an example TILT-UP AND PRECAST CONCRETE DAILY CHECKLIST Sme PCBUs ask sub-cntractrs t cmplete a daily checklist during the installatin f tilt-up r precast panels. The checklist identifies wh is respnsible fr each item (eg drawings, pre-erectin checks, panel lifting and erectin, and temprary bracing). The respnsible party initials each sectin, r attaches dcumentatin, t cnfirm that each item has been inspected and/r actined. See Appendix K f these guidelines fr an example. DOCUMENTATION FOR STRUCTURAL DESIGNER: WHAT TO CHECK Has the head cntractr given the fllwing dcumentatin t the structural designer: shp drawings? a wrk plan, setting ut hw the wrk will be carried ut, alng with any related infrmatin, instructins r diagrams? a site and services plan? an emergency plan? erectin dcumentatin? structural and precast cncrete element dcumentatin? drawings shwing the supprting structure f precast units? lading infrmatin? Page 63

64 instructins fr use, strage and maintenance f plant and equipment (where applicable)? a cpy f any reprt, licence r authrity required t carry ut precast cncrete cnstructin wrk? 7.7 OTHER DOCUMENTATION Other dcumentatin that shuld be accessible n site includes site-specific dcuments and recrds, including the emergency plan and the items listed in the table in 5.2 f these guidelines. Page 64

65 SECTION 8: MANUFACTURING The precast manufacturer and ther PCBUs invlved in the design, transprt and erectin prcesses shuld wrk tgether t plan the intended cnstructin and erectin sequences befre the precast cncrete elements are manufactured. As upstream PCBUs, precast cncrete manufacturers must, s far as is reasnably practicable, make sure the precast cncrete elements they manufacture are withut risks t the health and safety f peple using them fr the purpse they were manufactured fr. Sectins f HSWA specify the duties f upstream PCBUs, including PCBUs manufacturing plant, substances, r structures. Upstream PCBUs have specific duties under HSWA arund testing, analysis, and infrmatin prvisin. See Sectin 8.4 f these guidelines fr mre infrmatin. 8.1 WHAT COULD GO WRONG? WHAT COULD GO WRONG? POSSIBLE CAUSES Elements breaking during manufacture Manufacturing and/r design errrs. Inadequate cncrete strength. Inability t handle transprt stresses. Inability t handle rtating stresses. Incrrect installatin f lifting inserts. Incrrect installatin f steel reinfrcing. Wrkers suffering musculskeletal injuries (eg sprains and strains, back injuries, abdminal hernias) when handling elements Wrkers being expsed t substances harmful t health at unsafe levels Using inapprpriate techniques when handling elements (eg nt using the right equipment fr the jb) Nt using apprpriate cntrl measures t minimise expsure t substances cmmnly used in precast cncrete manufacture (including cncrete, curing cmpunds and release agents). Gd planning will ensure that precast cncrete elements are manufactured efficiently, safely and t specificatin, and that resurces are prperly allcated. Infrmatin abut the wrk t be undertaken shuld be readily available and clear. Page 65

66 8.2 THE PRECAST MANUFACTURER The precast manufacturer and ther PCBUs invlved in the design, transprt and erectin prcesses shuld wrk tgether t plan the intended cnstructin and erectin sequences befre the precast cncrete elements are manufactured. The cnstructin prgramme and any updates shuld be cmmunicated t the precast manufacturer prmptly. Changes t the cnstructin prgramme may cause strage r prductin prblems. The precast manufacturer needs t knw the client s requirements. The head cntractr gives the precast manufacturer the relevant drawings, specificatins and wrk prgramme. This includes any amendments, ntices t tenderers, agreed variatins and all ther infrmatin. The precast manufacturer manufactures the precast element nce a cmpetent persn has apprved the shp drawings. All lifting shuld be carried ut in accrdance with standard perating prcedures and wrk plans. The precast manufacturer: makes sure the apprpriate cncrete strength is achieved befre demulding and lifting ensures all lifting inserts (including thse with special designs) have been installed in accrdance with the manufacturer s installatin instructins and in cmpliance with the apprved shp drawings determines and ensures safe lifting and handling f precast elements in the precast yard prvides relevant paperwrk t the head cntractr befre the precast cncrete leaves the precast yard/is ffladed at site; this may include a Manufacturer s Statement f Cmpliance. Plant and equipment shuld be well-laid ut t ensure efficiency and safety fr wrkers. Fr example, casting beds shuld be well-lcated t ensure a sensible flw f wrk and safe lifting. Wrkers must be given apprpriate training, r be adequately supervised, t ensure they understand their rles and respnsibilities. Fr example, wrkers in charge f plant and equipment must be apprpriately trained and certified. Page 66

67 8.3 SHOP DRAWINGS AND APPROVALS Shp drawings (see Sectin 7.3 f these guidelines) shuld include all details needed t manufacture a precast cncrete element. The head cntractr, the precast manufacturer and the erectin sub-cntractr shuld tgether decide the prpping, bracing and any special lifting requirements. The head cntractr shuld check and apprve the drawings befre cncrete is cast, r give the shp drawings t the structural designer fr apprval r review. If the precast manufacturer suggests using a cncrete grade and/r additinal reinfrcing that differs frm the structural designer s specificatins, the head cntractr shuld ask the structural designer t apprve the change befre the cncrete is manufactured. If additinal inserts are required, the head cntractr has t clearly cmmunicate the requirements t the precast manufacturer in time t incrprate them int the manufacturing prcess. 8.4 PRECAST MANUFACTURER S DUTIES As an upstream PCBU, a precast cncrete manufacturer s duties include making sure that the elements they prduce are withut risks t the health and safety f persns using them fr the purpse they were manufactured fr, including during transprtatin t the site. The manufacturer must als prvide adequate infrmatin abut the element s purpse, any testing and examinatin results (see belw), cnditins fr use, and hw the panels will be handled. Cnsideratin shuld als be given t hw the panels will be transprted. The erectin crew requires infrmatin necessary fr handling elements n site, including: special rigging requirements temprary prpping requirements limitatins r restrictins n handling r strage TESTING The precast manufacturer must undertake, r arrange the undertaking f calculatins, analysis, testing r examinatin that may be necessary t ensure the precast cncrete elements are withut health and safety risks. They must prvide instructins abut hw the elements shuld be used and any analysis r test results, r cnditins f use, t make sure there are n risks t health and safety. EXAMPLES OF TESTS AND EXAMINATIONS THAT MAY BE CARRIED OUT - visual inspectin f a precast element fr damage, cracks r ther defects - measuring t ensure the dimensins are crrect - visual inspectin t cnfirm that lifting inserts are crrectly placed - testing whether an element can be lifted withut cracking. Page 67

68 8.5 OPTIONAL PRECAST MANUFACTURER S STATEMENT OF COMPLIANCE The PCBU wh manufactured the element shuld be satisfied that the element is fit fr purpse (built t the engineer s specificatin) befre sending it t the site. The precast manufacturer may prepare a Statement f Cmpliance befre transprting r erecting precast cncrete elements. This may take the frm f a Prducer Statement, Part 3 (als knwn as a PS3). This may fulfil the manufacturer s duty t prvide health and safety infrmatin abut their prducts r designs t ther PCBUs. A Statement f Cmpliance cnfirms the elements were manufactured in accrdance with the apprved shp drawings and t the design/specificatins specified by upstream designers. See Appendix L f these guidelines fr an example. Prviding a Statement f Cmpliance is ptinal. By sending an element t its destinatin, r allwing a manufactured element t be lifted, the manufacturer is cnfirming that the element is fit fr purpse. 8.6 CURING COMPOUNDS AND RELEASE AGENTS The strength, water-tightness and durability f cncrete will depend n it being sufficiently cured. Check that the release agents r curing cmpunds used during manufacturing are cmpatible with each ther, and with applied finishes and jint sealants, befre using them. Cnsider: slubility discluratin temperature effects. Apply curing cmpunds and release agents in accrdance with the manufacturer s instructins. Using release agents incrrectly may lead t high suctin lads r panels sticking t the casting surface SAFETY DATA SHEETS The precast cncrete manufacturer (and anyne else hlding a hazardus substance) must have a safety data sheet (SDS) fr every hazardus substance supplied t their wrkplace fr the first time. First time als means: when a substance is supplied fr the first time in five years when a substance is supplied fr the first time after a change t the SDS. Page 68

69 The precast cncrete manufacturer (and anyne else hlding a hazardus substance) needs t make sure that the SDS is available t: wrkers in the areas where they wrk emergency wrkers wh culd be expsed t the substance in an emergency anyne else wh culd be expsed t the substance. 8.7 MOULDS AND CASTING BEDS MOULDS Frmwrk r muld design can have a direct bearing n hw cncrete elements are cast and handled, and n the lads impsed during manufacture. Nte that: Surface finish requirements can influence the preferred rientatin f a precast element in the muld. Mulds fr elements like beams and clumns may require specialist prvisins t accmmdate pre-stressing. Suctin and frictin can be reduced by using high quality muld release cmpunds. Suctin n flat muld surfaces is increased by water presence. Frictin frces are increased by vertical r near-vertical sides n a muld. Precast manufacturers shuld be aware f the hazards and risks f the stressing peratin and have adequate cntrl measures in place t keep wrkers safe frm all risks VERTICAL MOULDS AND TILTING MOULDS Thin, lightly reinfrced elements are ften cast in vertical mulds, r hrizntal mulds tilted t vertical befre the element is lifted ut. Elements cast in this way shuld be stred, transprted and handled near-vertical at all times. If laid flat, they may be damaged by their self-weight alne SURFACE FINISHES Surface finish requirements can determine the preferred rientatin f a precast element in the muld. The finish quality f a vertical muld face may be less than that cast against a hrizntal surface. Tw-stage casting is ften used t avid this prblem LIFTING FROM CASTING BEDS When lifting precast elements frm a casting bed, allw fr suctin r demulding frces. The centre f the lifting inserts shuld cincide with the centre f gravity f the precast element. Page 69

70 8.7.5 ASSEMBLY AND RELEASE Remvable sectins f mulds are nrmally attached with blts, clamps, magnets r wedges. Majr items f embedded hardware, threaded inserts and dwel cnnectrs are ften blted t the muld. There shuld be an errr-prf system fr checking all blts are remved befre lifting the element frm the muld. Failing t remve blts is a cmmn cause f lifting insert failures. 8.8 MANUFACTURING TOLERANCES Table 5.1 in NZS 3109 (Cncrete Cnstructin) gives tlerances fr precast cncrete elements. Additinally, the table belw shws the recmmended tlerances fr lcatin f lifting inserts cast int precast cncrete elements. Type f unit Piles Flring units Beams Clumns Wall panels Insert lcatin 150 mm alng the length 150 mm alng the length 200 mm alng the length 50 mm alng the width 200 mm alng the length On the end: 50 mm On the face: 50 mm in any directin On edges: 50 mm lngitudinally, 10 mm acrss the thickness Nte: Lcatin acrss the thickness may be restricted by edge reinfrcing r edge details and the distance t the nearest edge will affect the capacity f the insert. Table 3: Recmmended tlerances fr lcatin f lifting inserts cast int precast cncrete elements Page 70

71 SECTION 9: HANDLING, STORING AND TRANSPORTING Handling, transprting and erecting precast cncrete elements can pse a risk t peple s safety, and a risk f damage t the elements. The pssibility f prgressive cllapse shuld be cnsidered at all stages. Methds f handling and string will depend n the type f precast cncrete element. Careful planning is required. Page 71

72 9.1 WHAT COULD GO WRONG? WHAT COULD GO WRONG? Elements falling r cllapsing (eg the uncntrlled cllapse f elements r persn being caught between an element and anther bject) causing severe crush injuries Wrkers suffering musculskeletal injuries (eg sprains and strains, back injuries, abdminal hernias) when handling elements (eg lifting, lwering, pushing, pulling, carrying, thrwing, mving, restraining, r hlding elements) Wrkers being expsed t substances harmful t health at harmful levels Wrkers falling frm height (eg frm A- frames) when handling elements POSSIBLE CAUSES Prly stred elements (eg prly maintained A-frames r ther strage equipment, incrrectly stred frames, elements stacked the wrng way). During transprtatin having: - uneven, unsecured r verladed racks r supprt frames - nncmpliant lifting systems - damaged elements - vehicles tipping due t a high centre f gravity causing rll-ver. Adverse weather cnditins (eg strng wind). Difficult site access, pr grund cnditins r uneven terrain causing the vehicle r lad t becme unstable. Using inapprpriate techniques when handling elements (eg nt using the right equipment fr the jb). Handling elements still cntaminated with substances cmmnly used in precast cncrete wrk including curing cmpunds and release agents. Nt using apprpriate equipment t reduce the risk f a fall. Equipment nt being inspected r wellmaintained. Fr infrmatin n wrking at height: WrkSafe s best practice guidelines Wrking at Height in New Zealand. Page 72

73 9.2 HANDLING, STORING AND TRANSPORTING Handling, string and transprting precast cncrete includes: remving precast cncrete frm mulds transprting precast cncrete elements t temprary strage mving frm temprary strage and lading fr transprtatin lading nt the means f transprtatin (eg a trailer) transprting by rad, rail r ver water mving frm transprtatin t temprary site strage mving frm temprary site strage t final lcatin erectin at the jb site (nce cncrete reaches the required strength). 9.3 THE HANDLING PROCESS HSWA requires that wrkers handling precast cncrete are adequately trained r supervised t carry ut all required tasks. This may include: hking up anchr pints using any lifting devices (eg gantry cranes) mving precast cncrete withut causing harm r injury t themselves r thers. The handling prcess depends n the: psitin f the casting muld (that is, vertical vs. hrizntal casting) minimum cncrete strength fr demulding, delivery and erectin adequacy f the design reinfrcement t resist handling stresses size and weight f the precast cncrete element number, size and lcatin f lifting pints and type f inserts/devices lifting methd, type f lifting equipment and crane capacity supprt pints fr strage and transprtatin. Handle precast cncrete elements apprpriately fr their shape and size, t avid excessive stress r damage. Different sets f lifting pints and cast-in devices may be used fr varius handling stages. Minimise the chance f impact between elements. Page 73

74 9.3.1 CONCRETE STRENGTH FOR HANDLING The precast manufacturer can use the Manufacturer s Statement f Cmpliance t cnfirm the cncrete strength t the persn transprting and/r erecting the tilt panels. The cncrete strength may be determined frm match cast cncrete test cylinders, histrical recrds, r impact hammer tests. Cncrete test cylinders have t be stred clse t the cncrete element t replicate the same cnditins as the cncrete element. Letting cncrete dry ut, r prlnged cld weather, can slw the strength gain f cncrete. See als Sectin f these guidelines which cvers the minimum strength fr lifting frm mulds. Precast cncrete is at higher risk f damage if it has nt reached its full designed strength befre handling. Remve precast cncrete frm mulds nly after the cncrete strength has reached the minimum strength required fr lifting. A cmpetent persn (such as a rigger) shuld give apprval befre a precast cncrete element is lifted. Prvide temprary bracing r strngbacks fr elements where required AVOID MULTIPLE HANDLING AND RELOCATION Precast cncrete is prne t damage each time it is handled r mved. The erectin sequence shuld minimise multiple handling. Careful planning and scheduling will reduce the need t handle and relcate precast cncrete elements. WrkSafe recmmends lifting precast elements int their final psitin when they are delivered, rather than putting them in temprary strage n site. Talk with the head cntractr befre handling r relcating a precast cncrete element. Make sure all cntrl measures fr safe handling, string and transprtatin are in place. Fllw a system if multiple handling cannt be avided. Fr example, stack units as near as pssible t their final fixed psitins. 9.4 STORING, STACKING AND SECURING Incrrect stacking and strage even fr a shrt time can damage precast cncrete elements. The damage may nt be bvius right away. String r supprting elements the wrng way can cause permanent defrmatin that makes elements unusable. A cmpetent persn (such as an engineer) shuld: decide hw and where elements are stred design and certify racking systems. Page 74

75 The design f strage and transprt frames shuld meet standards utlined in: NZS 3101: New Zealand cncrete structures standard series NZS 3404: New Zealand steel structures standard series AS/NZS 1170 series: New Zealand structural design actins standard series. Stre precast cncrete elements n suitable supprts n firm, level grund that is nt likely t cllapse under the weight f the elements. The grund cnditins in the precast yard r n site will influence hw high the elements can be safely stacked. Wind znes may affect the stability f stred elements. Obtain apprval frm a cmpetent persn befre string a precast cncrete element n a suspended flr slab r beam. If apprval is nt received, return the element t grund level. Elements shuld nt be stacked at a height that culd make the stack unstable, particularly if uneven settlement culd cause the stack t lean. Stack similar length elements tgether, t avid the need t climb nt stacked elements t secure chains r ther means f lifting. Cnsider hw high a persn can reach t pass lifting chains r slings arund the elements. If precast cncrete elements are stred in areas where vehicles are mving, prtect the elements with bllards r ther physical barriers, and prvide apprpriate warning signs. If supprt pints are critical fr stacking elements, transprt r lng-term strage, the lcatins fr dunnage r supprt shuld be nted n the shp drawings r n the precast layut drawing. Dunnage is the wrd used t describe timber r ther material used under r between precast cncrete elements. See Sectin f these guidelines fr mre infrmatin. When stacking elements, run bearers at 90 t the span f the flr n which they bear. When pssible, place bearers abve the wall r supprting the precast flring. When string multiple elements, fllw any specific instructins. Fr example, manufacturers may specify the maximum number f items in a racking r strage system, r the maximum weight f stred elements. Avid placing further lads n flrs already carrying stacked cmpnents (eg bricks, blcks, r ther building materials). Place elements that have details (eg hles) at the tp f stacked elements, r stack them separately, t prevent damage. If infill blcks are nt laded n pallets, stack them n sheet plywd r similar material t prevent fracture. Place infill blcks abve the bearing walls, r in a similar lcatin, t ensure gd lad distributin. They shuld nt be stacked at midspan. D nt stack units n partially cnstructed steel frames r structures, r in areas that allw fr displacement thrugh accidental cntact with the units. Page 75

76 9.4.1 DUNNAGE In these guidelines, dunnage means timber r ther material used under r between precast cncrete elements t prevent damage r instability during strage and transprtatin, r t allw access fr unlading r handling. Precast cncrete elements shuld be separated by suitable dunnage t: keep elements ff the grund allw access between units t fit lifting frks r strps prevent damage frm cncrete-t-cncrete cntact. Arrange dunnage t avid twisting r distrting the elements. Each level f dunnage in a stack shuld be directly ver the dunnage beneath, s the weight f all elements is transferred directly thrugh the dunnage t the grund and n element is laded by elements stacked abve it. The bttm level f dunnage shuld transfer the lad t the grund r whatever surface it is n withut verlading it r causing excess settlement r deflectin. Settling can crack sme types f elements. Precast cncrete elements will cure at different rates when stacked, which may result in temprary staining r discluratin that culd take sme time t fade. Use nn-staining materials fr dunnage n surfaces that will be visible in the finished structure STACK AND STORE CORRECTLY Stack and stre precast cncrete elements crrectly t avid damage and distrtin. Elements stacked n the grund have t be supprted at apprpriate lcatins. Prestressed elements in particular can be damaged if supprted inapprpriately. Stre precast elements s that they retain their crrect shape. If elements are ut f shape while stred, r stacked incrrectly, even fr shrt perids, cncrete creep can cause permanent distrtin. Even minr misalignment can make elements unusable. The yunger the age that precast elements twist, deflect r defrm, the greater the permanent creep defrmatin. Time in strage can increase cambers f eccentrically prestressed elements t unacceptable levels. Differences in expsure during strage will cause differences t the shape f elements and t their appearance. This can affect the utside panel in a stack against a frame, and the tp element when elements are stacked n tp f each ther. If unplanned strage is needed, PCBUs shuld agree tgether n an acceptable strage methd and lcatin. If the elements are t be transprted t strage, be clear abut the type f elements t be transprted and check that the transprt will be fit fr purpse. Page 76

77 STORAGE: WHAT TO CHECK Have PCBUs string precast cncrete n site cnsulted, c-perated and crdinated with each ther abut: strage design? what the elements will be blted t? what the elements will be landing n? hw the elements will be prtected during strage? hw the elements will be prtected frm being kncked ver? hw ften the elements will be lifted r mved prir t final placement? STORAGE RACKS AND FRAMES Strage racks, frames and supprts shuld be designed fr the shape, size and weight f the precast cncrete element, and t resist the lads and frces applied t them. Design shuld cnsider wind znes and grund cnditins, and refer t the latest versin f the fllwing standards: New Zealand cncrete structures standard (NZS 3101) New Zealand steel structures standard (NZS 3404) New Zealand structural design actins standard (AS/NZS 1170) The apprpriate standard fr the materials used. Frames used t supprt precast cncrete elements during transprt, whether they are part f the transprt vehicle r an add-n, shuld be adequately secured and designed t withstand any frces applied during lading, transprt and unlading. An engineer shuld apprve design f all static strage racks and frames used t stre r transprt precast elements, including tast racks and A-frames. Figure 5 shws a typical A-frame. Page 77

78 Figure 5: A typical A-frame A cmpetent persn shuld cnstruct racks and frames, and cmplete annual certificatin requirements. They shuld check racks and frames will remain stable when elements are placed n them. Wrkers lading the rack shuld be able t see, r quickly access, the certificate and rating. The certificate shuld shw: the lading and cnfiguratin used as the basis fr design maximum lad capacity/rating and any restrictins maximum size and weight f individual precast elements that can be stred whether wrk can be dne n the elements while in the racks limits n grund slpe if relevant required grund strength if relevant. Sme racks used fr n-site strage can als be put n the back f trucks. If s, this shuld be specified within the transprt requirements. Rack lifting pints shuld als be rated and certified by a cmpetent persn. Peple lading the rack shuld have quick access t this certificate and rating. WrkSafe recmmends that a Jb Safety Analysis (JSA) r similar prcess is carried ut befre lading and unlading precast elements int and ut f racks and frames. Page 78

79 Only wrk n precast elements in a racking system when: n-ne can be injured by falling elements there are n ther significant hazards, such as ther peple wrking near the strage area. Where a precast panel is t be supprted by a frame but will nt bear nt bth feet f the frame, particular care is required t ensure the frame remains stable. Make sure the frame is nt destabilised by verlading n ne side at any stage during lading r unlading. 9.5 TRANSPORTING TRANSPORT CONTRACTOR The transprt cntractr is respnsible fr: planning the delivery rute btaining any permits needed safely securing the lad fr transprtatin transprting the cncrete frm the precast yard t the installatin site NEW ZEALAND TRANSPORT AGENCY (NZTA) COMPLIANCE The transprt cntractr shuld be familiar with: NZTA s Vehicle Dimensins and Mass (VDAM) Rule. See NZTA fr the current versin. NZTA s The Official New Zealand Truck Lading Cde: a cde f practice fr the safety f lads n heavy vehicles. It prvides wners, drivers, peratrs and lading staff with guidance abut basic safety principles and precautins that must be taken t ensure that cmmn lads are transprted safely. NZTA s Cde f Practice fr Temprary Traffic Management (CPTTM): this describes best practice fr the safe and efficient management and peratin f temprary traffic management n all rads in New Zealand. Check and maintain New Zealand Transprt Agency (NZTA) cmpliance during all transprtatin phases, including areas where the public has access. If elements will be cast ff-site, the designer shuld cnsider NZTA authrity limits n length, width, height and weight, and available transprt equipment. The Land Transprt Act 1998 sets limits t the wrk time hurs fr a driver f a vehicle that requires a class 2, 3, 4, r 5 licence, r is used in a transprt service (ther than a rental service), r carries gds fr hire r reward. Fr example, when Mbile Crane Operatrs are driving t and frm a site, PCBUs must allw time fr the required rest breaks. See the NZTA website fr infrmatin abut wrk-time and lgbk requirements. Page 79

80 9.5.3 PLAN AHEAD Delivering precast cncrete elements safely t the wrkplace requires planning and c-peratin between PCBUs, particularly the transprt cntractr, the head cntractr and the erectr. Ntify the transprt cntractr abut transprtatin and delivery requirements, as well as any limitatins, s that suitable vehicles and drivers can be scheduled. Mass and height shuld be cnsidered t ensure stability f the lad. Cnfirm that the element has reached sufficient strength befre transprtatin. Cnsider specific design cmpnents that may affect transprtatin, including the stability f lng r unusually shaped elements. A purpse-built trailer shuld be the first chice fr transprt, if available. Figure 6 shws a typical step-dwn trailer with A-frames that may be suitable fr carrying cncrete panels. Figure 6: A-frames n a step-dwn trailer Precast cncrete elements shuld be adequately fixed and secured t the vehicle t prevent mvement r spills during transprt. Careful planning will reduce the need t transprt elements arund the site. T minimise risk, try t avid multiple lading and unlading. Have a traffic management plan in place when transprting precast cncrete elements t the wrkplace. Sectin f these guidelines recmmends what a traffic management plan shuld include. The transprt rute shuld be checked fr restrictins, and permits btained if required. The transprt cntractr shuld ensure drivers have clear instructins, are aware f risks and hazards, and are adequately trained t safely transprt precast cncrete elements. Page 80

81 9.5.4 PLANT AND EQUIPMENT Plant and equipment used during transprt includes: trucks, trailers, frk hists, cranes and ther lifting devices strage racks, frames and supprts (including A-frames and vertical strage racks) dunnage lad restraints (such as chains, slings, lifting clutches) A cmpetent persn shuld inspect all plant and equipment t ensure that it is safe t use and fit fr purpse. Any bent, wrn, crrded, r damaged plant and equipment shuld be remved frm service, repaired r replaced and re-inspected by a cmpetent persn (such as an equipment inspectr r rigger) befre it is used again. TRANSPORTATION: WHAT TO CHECK Has the transprt cntractr cnsidered: equipment needed? truck requirements and availability? permits required? transprt rutes, taking accunt f: bridges? winding rads? pwer lines n the way t the site, as well as n the site itself? size, shape and weight f lad/s? weight distributin and lad stability? lading arrangements, including any lad restrictins? lading system (eg racks r A-frames)? methds t adequately fix and secure elements t prevent mvement during transprtatin? hw t avid high impact lads n elements? recgnised rutes fr ver-dimensinal lads? differential rad cambers (bends, rises etc.) that may cause instability thrugh leaning, r distrtin in lng cncrete elements? site access limitatins? site-specific traffic management plan? (See belw.) delivery sequence and timing? Page 81

82 Are drivers: trained t transprt precast cncrete elements? aware f hazards and cntrl measures? aware f any dcumentatin they need t have befre lading? clear abut wh will give them any required dcumentatin, and what they need t d with it? SITE-SPECIFIC TRAFFIC MANAGEMENT PLAN The head cntractr shuld, as part f the HSMS, prvide a site-specific traffic management plan. The head cntractr shuld ensure that the traffic management plan is available n site at all times when wrk is being carried ut. Befre entering the cnstructin site, a driver shuld cnsult the traffic management plan. TRAFFIC MANAGEMENT: WHAT TO CHECK Des the traffic management plan include: layut and traffic flw n site? designated areas fr lading/unlading, reversing/turning arund? a designated safe area fr drivers while lading/unlading takes place? speed management? access under pwer lines; clearance required frm pwer lines during lifting? the shape, size, height and mass f the precast cncrete elements? ther activities n site when the precast cncrete elements are being transprted? ther vehicles n site? n-site safety f wrkers and ther persns (eg the public)? all-weather access fr the delivery vehicle? any permits needed (eg rad clsures)? the capacity f any permanent structures t carry transprt lads? prvisin fr temprary strage, if required? barriers, walkways, signs r ther requirements t guide traffic? Fr mre infrmatin WrkSafe s fact sheet Wrkplace Traffic Management. NZTA s Cde f practice fr temprary traffic management (CPTTM). Page 82

83 9.5.6 LOADING AND UNLOADING Vehicle lading must cmply with NZTA s The Official New Zealand Truck Lading Cde. A getechnical reprt may be required fr the lading zne, the unlading zne and the crane zne. Lading area The lading area shuld be n firm grund that is as level as pssible. Even a balanced lad can tip ver if it is n uneven grund. Lading Lad precast cncrete elements s that: identificatin marks are visible befre and during unlading unlading can be carried ut in the prper sequence weight is evenly distributed and the lad is stable the vehicle is nt verladed the lad is prperly secured. Unusual r irregular shapes A cmpetent persn may need t assess lading and restraint f elements with unusual r irregular shapes, high r ff-centre centres f gravity. Secure and restrain elements well Restrain elements n transprt vehicles s: each element is individually secured t prevent it falling frm the vehicle elements d nt mve during transprt elements d nt becme unstable when the restraint system is released n site. The restraint (eg chains, webbing straps) used shuld suit: the type and size f elements being transprted, and the type f vehicle being used. Cnsider whether special restraints r packing are needed: fr lng elements, especially when transprting ver large distances t prtect crners, sharp edges, r ther details. Wrkers shuld nt detach any securing rpes, chains r tarpaulins until the vehicle has stpped in the area agreed fr unlading. Page 83

84 Unlading The head cntractr and the transprt cntractr shuld tgether decide the mst suitable unlading sequence. Elements shuld be unladed in a way that des nt cause instability f the delivery vehicle r its lad. Check whether there is: a designated unlading area an exclusin zne arund the unlading area (t keep away peple wh are nt invlved in unlading). Keep elements transprted n A-frames restrained until their weight can safely be taken by the crane. D nt release an individual element until the crane has taken the initial lad f that element. Check fr damage Lk clsely at the elements t check that they were nt damaged during transit. Recrd and reprt any damage fund DRIVER S RESPONSIBILITIES The driver shuld be trained and cmpetent t manage the risks and hazards assciated with transprting precast cncrete. The transprt cntractr must prvide infrmatin, supervisin, training and instructin fr drivers. Transprting precast cncrete elements by rad, rail r water may create dynamic lads that cause the elements t shift. Once the precast cncrete elements are laded n the truck the driver shuld make sure they are well-secured t prevent mvement during transit. Restraints tend t lsen nce the lad settles and can als stretch (particularly webbing straps). The driver shuld stp and check the lad and restraints: shrtly after beginning the jurney, and again at further intervals, if travelling fr mre than ne hur. Make sure any surface the vehicle is ging ver is suitable. Transprting elements ver rugh grund can damage them if they are expsed t dynamic lads higher than they were designed t handle. The grund shuld be strng enugh t stp the wheels settling, and any slpe shuld nt make the vehicle r its lad unstable. 9.6 SITE ACCESS, CONDITIONS AND LIMITATIONS Befre a vehicle arrives n a wrk site, PCBUs (eg the transprt cntractr and head cntractr) shuld refer t the site traffic management plan and then agree n access t and arund the site. Page 84

85 The driver shuld refer t the traffic management plan befre driving ff a public rad and nt the site. It is the driver wh decides whether it is safe t enter the site. The driver shuld be cnfident that their vehicle can travel safely n the access prvided. ON-SITE ACCESS: WHAT TO CHECK Have the relevant PCBU/s: rdered apprpriate cranes? cnfirmed crane access? cnfirmed suitable access fr the delivery vehicle(s)? identified hazards (eg trees, pwer lines)? Have the relevant PCBU/s: identified risks? identified areas where access shuld be restricted? cnfirmed if temprary n-site strage is needed? cnfirmed all lads can be accmmdated including delivery lads, placing and erecting lads? checked: sil strengths? adequacy f site cncrete t resist lads? adequacy f cncrete fr attaching prps and braces, including in- r n-grund mass blcks, flr slabs and ther structural items? made sure all relevant wrkers knw the erectin sequence? made sure temprary prpping and bracing requirements are in place accrding t plans? prvided a cpy f the plans? received (if required/available) the Manufacturer s Statement f Cmpliance fr the precast cncrete elements being delivered, cnfirming the elements have been manufactured in accrdance with cntract requirements? checked the weather frecast fr the site during the scheduled delivery time? Page 85

86 DRIVERS: WHAT TO CHECK Has the driver: checked that access is suitable fr the size and weight f their vehicle? checked that all rad surfaces are suitable fr vehicles t drive n, including the lading site and the delivery site? cnfirmed whether the rad shulder is able t supprt the lad? The lad can rll if the driver pulls ver t let cars pass and the shulder cannt supprt the lad. been made aware f identified hazards (eg sft grund, uncmpacted fill r verhead bstructins)? asked fr and received any dcumentatin that relates t the element, such as the ptinal Manufacturer s Statement f Cmpliance? Page 86

87 SECTION 10: ERECTING Safe erectin f precast cncrete elements depends n careful planning. All peple wrking with precast cncrete shuld be aware f the risks. Failure t erect precast cncrete elements crrectly and safely can result in serius harm r death. A PCBU must ensure, s far as is reasnably practicable, the health and safety f wrkers, and that ther peple are nt put at risk by its wrk. Reasnably practicable means a PCBU des what is reasnable in their circumstances t ensure health and safety. This is the primary duty f care WHAT COULD GO WRONG? WHAT COULD GO WRONG? Elements falling r cllapsing (eg the uncntrlled cllapse f elements r persn being caught between an element and anther bject) causing severe crush injuries Undergrund and verhead services and structures (eg undergrund cables, water, gas r sewage pipes, verhead pwerlines) are cntacted r damaged during erectin resulting in injuries, electric shck, r death POSSIBLE CAUSES Structural cllapse Failure f temprary wrks Inadequate structural capacity f fundatins Elements have been damaged r weakened (eg by mdificatins r repairs) Adverse r extreme weather cnditins including strng wind and heavy rain (eg wind speed may exceed specificatins fr the safe erectin f precast cncrete elements; wet weather may cause instability in the crane platfrm r erectin area) Crushing undergrund cables, water, gas r sewage pipes during digging f fundatins. Striking verhead pwerlines when mving a precast cncrete element. Referring t utdated service mark-uts. Page 87

88 WHAT COULD GO WRONG? Wrkers suffering musculskeletal injuries (eg sprains and strains, back injuries, abdminal hernias) when handling elements (eg lifting, lwering, pushing, pulling, carrying, thrwing, mving, restraining, r hlding elements) Wrkers being expsed t substances harmful t health at unsafe levels Wrkers falling frm height (eg frm A- frames) when erecting elements POSSIBLE CAUSES Using inapprpriate techniques when handling elements (eg nt using the right equipment fr the jb) Handling elements still cntaminated with substances cmmnly used in precast cncrete wrk including curing cmpunds and release agents Nt using apprpriate equipment t reduce the risk f a fall Equipment nt being inspected r wellmaintained Objects falling frm height nt wrkers Unrestrained bjects (eg tls) Vehicles injure wrkers Inadequate site traffic management plan Lack f designated lading/unlading areas Insufficient lighting; vehicle nt easily seen r heard (eg n rtating light, n reversing alarm) Vehicles that are nt well-maintained Inexperienced r untrained drivers 10.2 ERECTOR/ERECTION TEAM (INSTALLER) The erectr: wrks with the precast manufacturer, the head cntractr and the cmpetent persn respnsible fr erectin design (see Sectin 6.2 f these guidelines) t decide n the erectin sequence and safe wrk practices prduces and briefs erectin crews n the HSMS inspects precast cncrete, reviews the Manufacturer s Statement f Cmpliance (if prvided), and reviews erectin plans/rigging drawings cnfirms clutches are cmpatible with inserts and inspects all rigging gear prir t use (fr example, face-lift clutches shuld be used n face-lift inserts) erects cncrete elements and installs temprary bracing checks trque n brace lifting inserts where applicable checks lifting inserts and surrunding cncrete fr wear and damage, and suitability fr lifting Page 88

89 ensures the precast elements are secured in accrdance with the erectin plan befre handing ver t the head cntractr. Any variatins r mdificatins t the erectin sequence shuld be apprved by a cmpetent persn ERECTION PLANNING ERECTION CREW The head cntractr shuld ensure cmpliance with any relevant regulatins when putting tgether an erectin crew fr handling and erecting precast elements. The erectin crew shuld include: an erectin crew supervisr respnsible fr safety, rigging, placement, prpping, unhking a cmpetent crane peratr a cmpetent dgman/rigger. Hlding a natinal certificate is ne way f demnstrating cmpetency. A persn with dual qualificatins may functin as bth a rigger and a dgman. Additinal skilled labur may be needed t help with element erectin r placement. A supervisr r cmpetent persn frm the erectin crew (such as a rigger) shuld be respnsible fr directing and c-rdinating the erectin sequence. Assign enugh peple t each jb, taking int accunt the weight and distance invlved PLANNING THE CONSTRUCTION AND ERECTION SEQUENCES Befre erecting precast cncrete elements, the head cntractr shuld wrk with ther PCBUs t plan the cnstructin and erectin sequences. Planning fr safe erectin f precast cncrete elements shuld cver, but nt be limited t: hazards, risks and cntrl measures wrk plans and HSMS casting and delivery sequence erectin sequence lift plan Page 89

90 site limitatins and features, such as: street access verhead bstructins, particularly verhead pwer lines at r adjacent t the cnstructin site suspended surfaces and basements undergrund services cmpactin f site surface areas precast cncrete element sizes crane size, cnfiguratin, mbility and access wrking radius f the crane (shwn n a crane layut drawing) sign-ff fr shre lading by a cmpetent persn visual inspectin f rigging and all assciated equipment height access equipment apprpriate t the cnstructin methds structural stability during erectin, including prpping and bracing requirements (eg length) specificatin f crrect lifting inserts/cast-in cmpnents transprt requirements ERECTION PLANNING: WHAT TO CHECK Des the erectin plan address all aspects f the erectin prcedure? Is the site clear and safe fr all trucks (including cunterweight trucks) and crane/s access and assembly? Is there a cmpacted hard-fill ramp at a suitable gradient? Has the crane perating area been cleared t prvide enugh rm fr: crane utriggers? cunterweight tail swing? slew path and under hk height? verhead bstructins, including verhead pwerlines? Can the crane platfrm supprt the lads impsed by the crane during peratin? Are supprt methds, including falsewrk: adequate? in the crrect lcatin? Have the lcating dwels r ther hrizntal restraints been fitted befre lwering the precast cncrete elements? Is there enugh clear space fr safely prpping and bracing precast cncrete elements? Page 90

91 ERECTION PLANNING: WHAT TO CHECK (cntinued) Are the recmmended braces fitted t the elements? Have brace fundatins reached their required strength befre elements are erected? If strngbacks are required, are they available and crrectly installed? Are cntrl measures in place fr safely wrking at height? Are there enugh prperly trained erectin crew members? Has an exclusin zne been set up fr the wrking area? Are the weather cnditins suitable fr erectin? Is a Manufacturer s Statement f Cmpliance required? Is a traffic management plan in place? 10.4 PROPPING AND BRACING The head cntractr cnsults with the precast manufacturer and erectin subcntractrs t decide what prpping, bracing, n-site lifting and handling is needed, including any special lifting prcedures. The head cntractr r the sub-cntractrs may als have special requirements fr prpping and bracing t ensure stability during cnstructin. Within the erectin dcumentatin, prpping and bracing designs have t shw the requirements fr temprary supprts. The head cntractr shuld mnitr climate cnditins. High winds, heavy rain r ther adverse weather events cmprmise the ability f prpping r bracing systems t resist lads. This may be due t lads being higher than allwed fr in the design, r the capacity f supprt systems being reduced PROPS A prp, whether custm-made r generic, is used t temprarily supprt a precast cncrete element. Prps are cmmnly used t supprt flrs and beams. Prps may be needed t: prvide temprary gravity lad supprt during cnstructin reduce the self-weight deflectin f precast flring systems while the castin-place tpping cncrete is placed and cured prevent trsinal instability r rtatin f beams laded alng ne edge prvide fine adjustment f the precast element t the crrect level while freeing the crane quickly fr the next lift supprt temprary cnstructin lads that exceed the design capacity f any part f the structure. Page 91

92 Unless specifically nted therwise, all temprary prpping shuld: be in place, adjusted t the crrect levels allwing fr any required cambers, and fully braced befre beginning erectin fully supprt all cnstructin lads including the full self-weight f the cmpleted flr system and pssible lcal cncentratins f lad during cnstructin. Prpping fr beams shuld allw fr pssible changes t the lad distributin during the cnstructin prcess. Permanent gruting r mrtar packing f precast cncrete supprt pints requires care and supervisin t ensure that the requirements fr strength and durability are met BRACES Braces are usually placed diagnally and firmly attached t prvide stability and resist lateral lads. Lateral bracing is smetimes used t resist panel base mvement, wind and ther lateral frces. Braces may take the frm f prprietary prps (ften adjustable), scafflding, r specially designed cmpnents. Braces: may act in cmpressin and in tensin may have flexible end cnnectins t adjust t different angles may r may nt be adjustable in length are required t cpe with cyclic lads generally are nt vertical prevent verturning and resist hrizntal mvement. Braces are cmmnly used when erecting wall panels t resist wind and ther lads until panels are permanently fixed. (Prps are anther frm f supprt, typically used t supprt beams and flrs; see Sectin f these guidelines.) Brace cnnectins shuld be designed with a safety factr f 2.5 against failure. When pst-installed inserts are used t attach a brace, they shuld be designed with a safety factr f 3. D nt use defrmatin-cntrlled lifting inserts fr anchring braces, because: they have n additinal expansin (and therefre n lad capacity) after the initial setting prcess they fail withut warning and are highly sensitive t installatin prcedures. D nt use lifting inserts that rely slely n chemical adhesin unless each fixing is individually prf-tested t the wrking lad limit. Adjustable braces shuld have: safe wrking lads available at zer and maximum extensin stps n the threads t prevent ver-extensin. Page 92

93 Keep precast elements temprarily braced until they are adequately restrained r incrprated int the final structure. Unless deliberately designed and specified, bracing inserts shuld nt be clser than 300mm t the edge f the precast cncrete element r the bracing supprt. The distance t the edge may need t be increased fr larger elements, with instructins frm a cmpetent persn. Lcatin f the bracing inserts shuld allw the braces t hang vertically during lifting withut interfering with the lifting rigging. Fr the bracing insert, a minimum hrizntal displacement f 200mm frm the vertical line f the lifting inserts is acceptable. Precast cncrete manufacturers shuld nt substitute lifting insert types withut written apprval frm a cmpetent persn. Bracing insert requirements and precast cncrete element details shuld be shwn n the shp drawings. Cnsider the strength f the cncrete in the brace fting when designing bracing inserts fr fundatins. The cncrete strength required at erectin time has t be clearly specified n the erectin plan. Identificatin marks WrkSafe recmmends that braces have permanently fixed identificatin displaying the fllwing infrmatin: the supplier the mdel the batch. This allws the braces t be easily identified. Dcumentatin Recrds shuld shw hw and when the batch was last tested. The supprting dcumentatin fr the braces shuld be available n site. It shuld include the fllwing infrmatin: fr fixed length braces, the wrking lad limit (WLL), in kilnewtns (kn) fr adjustable length (telescpic) braces, the WLL, in kn, at maximum and minimum extensin. Fix bracing t the precast cncrete element befre lifting (where pssible). If braces are t be attached after the element is psitined, the crane shuld supprt the element while the braces are installed using an apprpriate access system. A minimum f tw restraints shuld be used n precast cncrete elements, unless clearly specified and detailed in the design dcumentatin. Where elements can be cupled tgether, ne central restraint t resist rtatin r tppling may be sufficient (subject t the cmpetent persn s apprval). Page 93

94 Braces shuld be attached t a flat surface which is capable f withstanding the applied lad. Check that there is sufficient temprary base restraint t prevent a sliding failure (kick-ut) at the base r supprt f the precast cncrete element. The panel weight may nt prvide base restraint. Check that lcating dwels and levelling shims are in the crrect place CHECK BRACING REGULARLY Check bracing regularly and immediately after an event such as an earthquake r strm t ensure the fixings are still secure and the system still cmplies with the erectin design. Bracing shuld be inspected and apprved by a cmpetent persn befre wrk resumes. The cmpetent persn shuld check structural integrity, braces and cnnectins, and fixing inserts BRACE CONFIGURATION As nted abve, WrkSafe recmmends using a minimum f tw restraints t supprt each precast element, unless clearly specified and detailed in the design dcumentatin. Precast cncrete elements supprted by a single brace may fail by rtating abut that brace. One brace can be used where anther part f the element is securely fixed t an existing part f a structure; hwever, this cnfiguratin needs t be specified by a cmpetent persn. Three r mre braces may be needed fr larger precast cncrete elements. Where mre than tw braces are used there is difficulty ensuring an even lad distributin. The design shuld make allwances fr the ptentially uneven lading where mre than tw braces are being used. It is cmmn t use tw braces at right angles fr narrw wall panels r clumns. Clumns are usually braced with ne brace in tw rthgnal directins that is, tw braces in all. When wall panels are tall and narrw, they may need t be braced with tw braces perpendicular t their flat face and restrained by bracing in the ther rthgnal directin fr stability. Fr wall panels, bracing pints are typically 67% f the height f the panel frm its base. Bracing design shuld cnsider the effect f the vertical cmpnent f the brace lad n the available frictin at the base. Wall panels shuld never be braced belw mid-panel height, unless carried ut under strictly cntrlled cnditins with special prvisins having been made t prevent base kick-ut r panel failure due t bending at the bracing pint. Page 94

95 Figure 7: Panels, mass blcks and braces BRACING INSERTS Bracing inserts are used t cnnect the brace t the braced element and the brace fting. They shuld be designed with a safety factr f 2.5 against failure f cncrete. If expansin anchrs are used, capacity is based n a factr f safety f 2.5 against the first slip. If pssible use cast-in inserts. Pst-installed mechanical lifting inserts can als be used. Alternative inserts include: mechanical fixings, such as undercut inserts and pst-installed fixings, used in accrdance with the manufacturer s recmmendatins by the manufacturer f the bracing insert lad-cntrlled (trque-cntrlled) expansin inserts with a permissible lad limited t 0.65 f the first slip lad. Figure 8 shws examples f expansin inserts acceptable fr anchring braces. Page 95

96 Figure 8: Examples f expansin inserts Expansin inserts are mre prne t installatin errrs than cast-in fixings. Ensure the manufacturer s installatin instructins are clsely fllwed. Pst-installed lifting inserts used t cnnect braces shuld be a type knwn as heavy duty high lad slip expansin lifting inserts, r lad-cntrlled where an increase in lad results in increased wedging frce. Defrmatin-cntrlled lifting inserts, including pst-installed lifting inserts and drpin (setting) impact lifting inserts, shuld nt be used as bracing inserts. Bracing inserts shuld be designed t resist all reasnably freseeable lads, including: cnstructin lads wind lads fr temprary structures in accrdance with AS/NZS Bracing insert capacities are sensitive t the: methd f installatin strength f the surrunding cncrete at the time f usage distance frm the insert t the edge f the precast cncrete element as well as the distance t penings, recesses r edge rebates prximity t surrunding lifting inserts laded cncurrently FIXING INSERTS The types f fixing inserts t be cast in t the precast cncrete elements shuld be specified n the shp drawings. A cmpetent persn, such as an insert manufacturer r supplier, shuld apprve any changes. Any further mdificatins made n site (such as drilling anchrs nt indicated in the plans) shuld nly be dne after cnsultatin with a cmpetent persn. Page 96

97 Fr cast-in r pst-installed fixings t brace fundatins, the capacity f the fixing may be less than the capacity f the brace itself, requiring additinal braces t supprt the cncrete element. Using a fixing with higher capacities may avid this LEVELLING SHIMS Levelling shims carry the full lad f the precast element and any lads applied t it prir t permanent fixing f the precast element. Shims shuld be manufactured frm a suitable durable material and be used n slid fundatins. Shims shuld nt be placed n thin layers f site cncrete. A levelling pad (cncrete fting) r a level bearing area is used t prvide a level seating fr the shims, as shwn in Figure 9. Precast cncrete elements shuld be designed t sit n lcalised shimming pints when initially erected. Using multiple shimming pints will nt ensure unifrm distributin f lad due t difficulties with cnstructin tlerances. Try t avid direct cncrete-t-cncrete r cncrete-t-steel bearing. This may result in edge spalling and cracking. See AS3850 fr additinal guidance re shims. Figure 9: Levelling shims The ttal height f each levelling shim (that is, the distance between the panel and the fting) shuld be a maximum f 40mm, unless specified by a cmpetent persn. Page 97

98 If errrs in fundatins and/r panel cnstructin lead t the height f the levelling shim being greater than 40 mm, then the shim height shuld be assessed by a cmpetent persn t cnfirm that the panel is still stable. It is pssible that the site assessment will be dne by a different cmpetent persn than the structural designer CRANES AND LIFTING EQUIPMENT As well as the hazards identified at the beginning f this sectin, ther hazards faced by crane peratins are shwn belw WHAT COULD GO WRONG? WHAT COULD GO WRONG? POSSIBLE CAUSES The crane culd tip ver The crane is set up n sft, unstable r unsuitable grund. The crane is nt set up level. The crane is psitined abve undergrund services. The utriggers f a mbile crane are nt fully extended r used as directed in the crane manufacturer s instructins. Insufficient cunterweights are used. Wind effects n the lad r crane during extreme events. The weight f the lad is calculated incrrectly. The structure f the crane culd fail. The rigging cmpnents are verladed. The lad swings r drps suddenly. The lad histed is beynd the capacity f the crane. The crane has nt been maintained prperly. The crane has nt been assembled prperly. The weight f the lad is calculated incrrectly. During the lift the bm f the crane culd hit peple, structures r ther plant in its path. There is insufficient clearance between the crane and ther structures r plant. The path f the lad is nt carefully planned. Exclusin znes are nt maintained and unauthrised peple enter the lift area. Page 98

99 WHAT COULD GO WRONG? The dgman/rigger, grund wrkers and/r crane peratr culd be electrcuted. Objects culd fall ff the lad being lifted and hit peple, structures r ther plant. POSSIBLE CAUSES The crane cmes in cntact with verhead r undergrund pwer surces. There is an arcing f electrical current when the crane cmes clse t pwer lines. Minimum apprach distances (MADs) nt fllwed. Material is nt prperly secured. The lad is rigged incrrectly. Faulty lifting inserts r cnnectrs. Exclusin znes are nt maintained and unauthrised peple enter the lift area. The lad culd be drpped. The lifting equipment has nt been maintained. The lifting equipment is nt fit fr purpse. The PCBU must ensure, s far as is reasnably practicable, that the crane and all lifting equipment is specifically designed t lift r suspend the applied lads. The apprpriate crane and lifting equipment is t be selected fr the tasks. The plant is t be maintained and peratrs and dgmen/riggers have the apprpriate skills and training CRANE CONTROLLER, CRANE OPERATOR AND DOGMAN/RIGGER A cntrller is the wner, lessee, sub-lessee, r bailee f a crane in a wrkplace. Cntrllers need t be knwledgeable abut crane peratins s that they can recmmend the best machine fr the lift. S far as is reasnably practicable, the cntrller must ensure that: cranes are in a safe cnditin and are perated safely cranes are inspected regularly and prperly maintained (as advised by the crane manufacturer) all peratinal cranes have a current certificate f inspectin issued by a recgnised inspectin bdy peratrs are cmpetent and have apprpriate training and experience. The crane peratr needs t have the knwledge and skills t perate the particular type f crane they are using. They can pick up the knwledge and skills thrugh a cmbinatin f training, qualificatins and experience. They shuld fllw the manufacturer s instructins cntained in the rating charts, manuals and perating prcedures prvided with the crane. The peratrs shuld fllw the cntrller s requirements and wrkplace plicies regarding regular and pre-start checks. They shuld never perate a crane until they are sure cnditins are safe. Page 99

100 The dgman/rigger is qualified t sling lads and direct the lifting and placing peratins f a crane. They ensure that the lad is safely rigged fr lifting and that the crane is directed safely fr all mvements f the lad. They shuld wrk with the crane peratr t understand the crane s ability and plan the lift OPERATING SAFELY AND EFFECTIVELY A crane has t be stable t perate safely and effectively. It has t be set up accrding t the manufacturers specificatins n grund that can supprt the weight f the crane and the suspended lad. Other factrs t be cnsidered include the slpe f the grund, and wind cnditins. Winds can affect the lad, which in turn can affect the crane s stability and structural integrity. Wind lading n large precast surface areas shuld be cnsidered. Fr example, wind can cause the lad t mve laterally. This mvement culd place side lading n the bm which may result in the bm cllapsing. In sme wind cnditins the peratr will need t reduce the crane s wrking wind speed fr large elements. Sme elements may nt be able t be lifted until the wind speed reduces. A tag line (see Figure 10) is ideal fr guiding elements during light winds. But if the wind frce is s strng that a wrker needs t lean and lug then the lift shuld nt g ahead. Figure 10: Wrker guiding panel using tag line The crane capacity required is affected by the distance frm the centre f rtatin f the crane t the centre f gravity f the precast element being lifted. The lad capacity f a crane decreases as the distance f lift frm the centre f rtatin f the crane increases. Fr all face-lifted tilt panels the true wrking radius f the crane may be up t 1.5 m mre than the final psitin radius f the panel. See Figure 11 fr mre infrmatin. Page 100

101 Figure 11: Crane wrking radius TILT PANELS Wherever practicable: lift tilt panels frm within the building envelpe s that the crane peratr can keep the rigging and lifting eyes in view at all times fix braces t precast cncrete elements befre lifting. A cmpetent persn (such as a manufacturer r supplier) shuld prvide an insert layut and rigging plan fr tilt panels, based n the design f the panels fr lifting. WrkSafe recmmends that this plan is available n site t ensure that the apprved rigging system matches the lifting design. A cmpetent persn, such as a rigger, may alter the plan t suit the rigging available LIFTING OPERATIONS Lifting peratins shuld be planned, supervised and carried ut by cmpetent peple. Objects falling frm height can injure r kill wrkers r thers. Page 101

102 The PCBU must take all practicable steps t ensure that equipment: is maintained in a safe cnditin is perated safely is perated within the limits that it was designed t perate within. Wrkers must be given infrmatin and training n health risks and safe use f the equipment. Equipment must nly be perated if it has a current certificate f inspectin issued by a recgnised inspectin bdy. See fr a list f recgnised inspecting bdies. In accrdance with GRWM Regulatins 24 and 25, a PCBU must manage risks assciated with wrk being dne under any raised r lifted bject, and manage risks assciated with falling bjects. Raised bjects include bjects lifted by cranes. PCBUs must fllw a prescribed risk management prcess t: manage risks t health and safety frm wrk under bjects raised r lifted by any means. manage the health and safety risks frm falling bjects that are reasnably likely t fall n and injure a persn. If a PCBU can t eliminate the risk, the PCBU must minimise it, s far as is reasnably practicable. Fr example by: limiting expsure t the drp zne under a raised bject, s wrkers nly enter the drp zne t secure prps when authrised securing prps t the panel prir t lifting designing the panel t ensure safe placement by the crane establishing exclusin znes fr ther persns, such as wrkers nt required fr the lifting peratins; see Sectin 10.8 f these guidelines. If it is nt reasnably practicable t prevent an bject frm falling freely r t use a system t arrest the fall, WrkSafe recmmends the creatin f an exclusin zne. This is a defined area where peple are nt allwed t g when particular wrk is being dne. Fr mre infrmatin WrkSafe s interpretive guidelines General Risk and Wrkplace Management, Part 2. See Sectin 2: The prescribed risk management prcess WrkSafe s Apprved Cde f Practice fr Cranes WrkSafe s Apprved Cde f Practice fr Lad-lifting Rigging Crane Assciatin f New Zealand s Crane Safety Manual fr Crane Operatrs and Dgmen Page 102

103 SUSPENDED SLABS Suspended slabs are nt nrmally designed t supprt cranes r heavy vehicles. If a suspended slab is t be used t supprt a crane r heavy vehicle, a Chartered Prfessinal Engineer (CPEng) shuld design the slab fr the pint lads applied by the crane s utriggers, wheel lads, r any ther cnstructin lads. A temprary prpping system may be required fr a suspended slab LIFTING PRECAST CONCRETE ELEMENTS One r mre cranes may be used t lift and place precast cncrete elements. Figure 12 shws tw cranes mving an element. Figure 12: Tw-crane lift When lifting a tilt panel, the lifting inserts and the rigging shuld be arranged s that when the panel is lifted it remains stable and the bttm edge remains hrizntal. Tilt panels may slide during the initial lift and sliding shuld be cntrlled. D nt use hps f reinfrcing steel fr lifting. Lwer lads gently t avid sudden impact LOAD RESTRAINTS AND LIFTING Any lad carried n a vehicle must be sufficiently restrained t prevent mvement caused by the frces as described in NZTA s The Official New Zealand Truck Lading Cde, see Lad restraints must prevent mvement f a lad under certain cnditins (eg during crnering) LIFTING ELEMENTS FROM DELIVERY VEHICLE The crrect lifting equipment shuld be n site t unlad precast cncrete elements. Equipment shuld be inspected befre use. Page 103

104 Befre attaching lifting equipment t precast cncrete, check the lifting inserts t ensure they are undamaged and cmpatible with the prpsed lifting equipment. Figure 13 shws a typical rigging system (lifting clutch and lifting anchr) fr a precast cncrete element. A suitable system shuld be in place t prevent wrkers falling frm vehicles while lads are being rigged. Check, recrd and reprt any damage t the precast cncrete befre fflading. The rigging system used n site fr each precast cncrete element shuld be as set ut in the erectin dcumentatin. Erectin dcumentatin shuld cver every aspect f the erectin prcess. Figure 13: Typical rigging system fr a precast cncrete element When unlading, d nt release individual precast cncrete elements until the crane has taken the initial lad f that element. Elements transprted n an A-frame shuld remain restrained until their weight can safely be taken by the crane. Fr mre infrmatin n rigging and lifting WrkSafe s Apprved cde f practice fr lad-lifting rigging Page 104

105 10.8 EXCLUSION ZONES An exclusin zne is a defined area where peple are nt allwed t g when particular wrk is being dne. Carry ut a risk assessment when setting up an exclusin zne. Use apprpriate signage and/r barriers t establish an exclusin zne, depending n ease f access and the likely presence f wrkers r thers. Perimeter fencing arund the site will help. Peple shuld nt be in an area where they culd be: struck if a precast cncrete element falls caught between an element and any ther hard surface. Only peple directly invlved in lifting elements (r related activities) shuld be in the exclusin zne when lifting takes place. The driver shuld be in a safe area away frm the truck during unlading. Lads shuld nt be suspended ver, r travel ver, a persn. If a ftpath, rad r ther access way is lcated in an exclusin zne, the public and all traffic shuld be prevented frm passing thrugh the zne while precast cncrete element wrk is being dne, until the elements are fully secured. This issue shuld be addressed in the planning stage RIGGING All lifting equipment shuld cmply with the requirements utlined in WrkSafe s Apprved Cde f Practice fr Lad-lifting Rigging. The precast elements as manufactured will have specific lifting and rigging prvisins r requirements. They may have inserts cast in t suit a particular rigging arrangement, r they may be intended t be lifted by slings r ther means withut using cast-in inserts. Ensure the rigging and lifting equipment available matches the particular requirements f each element. Setting up a rigging system fr erecting tilt panels and ther precast cncrete elements requires careful pre-planning. The erectr and the dgman/rigger shuld wrk tgether t select the rigging system that will cnnect the element t the crane. They have t ensure that the system can handle the frces it may be expsed t. Nte there culd be a number f rigging systems fr the same panel, at different times: fr demulding fr lading t transprt fr lifting/rtating/erecting n site. Page 105

106 All rigging shuld be inspected: annually by a cmpetent persn, such as a lifting tackle inspectr r a Lifting Equipment Engineers New Zealand Incrprated (LEENZ) member, and befre it is used. This means that the dgman/rigger shuld check the rigging befre lifting, particularly if steel wire rpe is used in the rigging system. Watch fr twist in wire rpes. The dgman/rigger shuld d a visual check t ensure the rlling blck cllar pin is intact and the cllar is nt lse. The centre pin n all rlling blcks (with ball bearings r plain bearings) shuld be lcked int psitin t stp rtatin by using a retaining system, such as a blt-n lck plate. Regularly check all parts f the rigging system fr damage and excessive wear r crrsin, t ensure they are suitable fr the lads being lifted LOAD EQUALISATION Take special care with rigging arrangements where lad equalisatin measures are required. Decide whether t equalise lads between lifting pints n precast elements such as beams r flat slabs. T prvide stability the centre f gravity f the precast cncrete element shuld be belw the lifting pints, as shwn in Figure Figures 14 and 15 reprduced with permissin frm Ancn. Page 106

107 Figure 14: Precast cncrete elements with centre f gravity belw centre f lift Cmmn lifting designs with fixed length slings require 3 r 4 lifting pints fr stability. Hwever, when using multi-leg (3 r mre) fixed length slings cnnected t a cmmn pint, the full lad shuld be taken by nly 2 f the lifting pints, as shwn in Figure 15 belw. Figure 15: Influence f nn-equalised rigging systems n distributin f lifting lads Page 107

108 The shrtest (black) slings share the lad while the (red) unladed slings are slack. When using three lifting pints, a cmpetent persn shuld determine the lad n each individual lifting pint cnsidering the lcatin f the centre f gravity f the element relative t the centrid f the lifting pints. Avid designs with multiples f 3 lifting pints because it is difficult t rig the system crrectly t guarantee equal lad distributin. Figure 16 shws ther pssible cnfiguratins fr lifting precast cncrete elements. 3 The rigging system shuld be designed t distribute equal lads t all lifting pints. Smetimes the design may require unequal lading n lifting pints, causing an increased lad t be applied t particular lifting inserts. This shuld be cnsidered when selecting the insert capacity, and the requirements shuld be clearly specified n the shp drawings. 3 Precast New Zealand and Crane Assciatin f New Zealand have additinal infrmatin and examples. Page 108

109 Figure 16: Examples f pssible rigging cnfiguratins fr lifting precast cncrete elements 4 4 Figure 16 images reprduced with permissin frm Smith Crane & Cnstructin Page 109

110 Single, duble and fur-leg slings are cmmnly used when handling precast cncrete elements. When selecting the sling capacity, the increased frce due t slpe f the sling and the change f directin at reeving pints shuld be cnsidered. The included angle between slings at reeving pints shuld nt exceed 120 degrees. Plan lifts s rtatin f the rlling blck under lad is nt required. Rlling (and ther) blcks need t be equipped with thrust bearings r separate swivel bearings if rtatin f rlling blck swivels under lad is unavidable. Blcks with standard plain bearings are nt intended t be rtated under lad. Arrange the rigging system t allw the precast cncrete element t lie in r near its crrect attitude fr erectin int the structure. In many cases, lads n inserts will nt be equal, and will vary as different stages between the initial lift and placement int its final lcatin. This particularly applies where the rientatin f the element changes r it requires rtatin. Cntact a cmpetent persn immediately if inserts are incrrectly lcated, faulty r missing, r if cncrete is prly cmpacted r cracked clse t lifting inserts CHRISTMAS TREE LIFTING Christmas Tree Lifting means lifting three r mre similar bjects (such as precast cncrete elements) hanging ne under anther, as shwn in Figure 17. This allws the safe and efficient use f cranes t place multiple cncrete elements, ribs r steel beams (fr example, t make up a flring system r a rfing system). Figure 17: Christmas tree lifting Lifting multiple bjects at nce reduces the number f lads being lifted and slewed ver the wrk site. The bjects lifted need t be unifrm (f similar dimensins and weight). The cmbined lad must nt exceed the capacity f the crane. Each bject has t be rigged independently f the thers. Each bject shuld be spaced apprximately 0.5m abve the ne belw. Page 110

111 The Jb Safety Analysis (JSA) shuld make it clear that extra precautins are needed. The PCBU must address the risk f wrkers being expsed t a suspended lad. T avid r reduce expsure, it is pssible t manage this risk by ensuring that all riggers stand t the side, r at the end f the lad, when placing each unit CONFIRM THE RIGGING SYSTEM Cnfirm that the rigger is using the crrect rigging system (as specified by the designer) and the right equipment. LIFTING: WHAT TO CHECK Is the rigging system designed t suit the spacing and layut f the lifting inserts fr preferred rigging cnfiguratins? Will lifting ccur in the directin specified fr the placement f the lifting inserts? Is the apprpriate rigging equipment available and serviceable, with a current inspectin tag? D braces interfere with the rigging? Are lifting inserts in the crrect lcatin? Have recesses been cleaned ut in preparatin fr lifting, s that lifting clutches can crrectly engage? Is the rigging system fr each precast cncrete element generally as set ut in the erectin dcumentatin? Is the lifting equipment cmpatible with the inserts cast in t the precast cncrete element? If the lifting clutches and the lifting inserts are frm different suppliers, has smene cnfirmed with the supplier f the lifting clutches and the supplier f the lifting inserts that the clutches and inserts are cmpatible? Are the lifting inserts clearly identified, t assist during lading and unlading? Are strngbacks required? If required, are they available? Is lad equalisatin required? Is any special handling required? Is apprpriate equipment available? Are lads and reach within the capacity f the crane? Take int accunt handling and lifting equipment, lad equalisatin equipment, strngbacks (if required), safe wrking radius, crane capacity, weight f the lad element including strngbacks and rigging, tilt f the panel and centre f gravity (COG). Page 111

112 Will elements need t be re-aligned/repsitined after lifting frm the delivery vehicle? If yes: Is there enugh rm available? Is the right equipment available? Are the erectin crew familiar with methds and restrictins applying t precast cncrete elements lifted withut cast-in inserts? If precast cncrete elements are being lifted withut cast-in inserts, is apprpriate equipment available? Has the cncrete reached the required cncrete strength as defined fr the lifting prcedure? Fr mre infrmatin WrkSafe s Apprved Cde f Practice fr Lad-lifting Rigging See Sectin 5.12: Inspectin LIFTING INSERTS AND CLUTCHES T minimise the chance f errr, cast-in cmpnents shuld be standardised and cmpatible fr all precast cncrete elements n an individual prject. If cmpnents that have been cast in fr permanent fixing f the precast element are t be used fr lifting r handling, r any ther use, care must be taken t ensure that such use will nt cmprmise their lng-term perfrmance. D nt use impact driven cmpnents, including explsive charge driven cmpnents, fr lifting purpses LIFTING INSERTS Lifting inserts are referred t by their wrking lad limit. Their actual safe lad may be less, depending n cnditins. The lad capacity f lifting inserts may be affected by: prximity t edges prximity t penings, recesses r edge rebates prximity t ther lifting devices that are laded cncurrently cncrete thickness strength f the cncrete the insert is embedded in at the time it is laded directin and type f lad: shear, cmpressin, r tensin embedment depth lad angles (especially fr edge-lifters) the presence f cracks Page 112

113 the prximity f reinfrcement r pre-stressing tendns methd f lifting (eg pick and carry) tensin stresses in the cncrete arund the insert length f chains and chain angle Steel reinfrcement bars are nt suitable as lifting lps and shuld nt be used fr that purpse. Sme high tensile strength steel bars have prperties that make them suitable nly t resist tensile frces and they shuld nt be used in any part f a lifting insert. Pre-stressing strand, while nt recmmended, may be used in a cntrlled manner if in cmpliance with recgnised standards. Every item f lifting equipment shall be clearly and permanently marked with its WLL. A unique identifying numbering system t clearly identify individual items shuld als be used. Sme types f lifting inserts require reinfrcing t develp their required lad capacity. Any reinfrcing shuld be used accrding t the requirements f these guidelines, the relevant standards, and installatin instructins specified by the lifting insert manufacturer. The design f the reinfrcing is t ensure that the lifting insert system will give the required factr f safety. Put in place a site prcedure t fllw if panels arrive n site with different lifting inserts r lifting inserts missing. Fr example: return the panel t the precast manufacturer, r ask the manufacturer t prvide an alternative lifting methd, and/r ask the manufacturer t prvide remedial wrks LIFTING CLUTCHES Lifting clutches shuld be designed s there is n chance f unintentinal clutch release during peratins such as element rtatin, particularly when clutches are fitted with remte-release lines. Lifting clutches are t be: designed with a factr f safety f 5 initially tested by the supplier t a factr f safety f 2 visually inspected fr damage r wear each day prir t use used nly with the type and size f inserts that they are cmpatible with made in accrdance with a valid internatinal standard r technical reference (such as CEN TR Design and use f inserts fr lifting and handling f precast cncrete elements) inspected at least every 12 mnths by a cmpetent persn, and a recrd kept f thse inspectins. Page 113

114 Inspectins shuld be made in accrdance with either the requirements in WrkSafe s Apprved Cde f Practice fr Lad-lifting Rigging r the requirements specified by the manufacturer whichever is mre thrugh. Testing f lifting clutches shuld include testing fr pssible misalignment r misplacement that culd cause the lad t be applied in an unintended way. All testing shuld be dcumented. All lifting clutches shuld have a recrd shwing the perid f test validity and maximum allwable capacity. LIFTING INSERTS AND CLUTCHES: WHAT TO CHECK Is all lifting equipment certified and in gd cnditin? Are the lifting clutches crrectly engaged befre lifting? Has the precast cncrete element reached the specified strength fr lifting, as per the shp drawings? (This may already have been dne if the element was manufactured ff-site.) Is the apprpriate rigging equipment available? This includes lifting beams and crrect attachments fr cast-in lifting inserts. Are recesses cleaned ut ready fr lifting? Are the lifting inserts in their crrect lcatin? Cntact the designer immediately if the lcatin isn t crrect r there are faulty r missing lifting inserts. The designer shuld fix the prblem and/r prvide a slutin ROTATION When precast cncrete elements need t be rtated befre they are placed, carefully cnsider, plan and dcument the methd f rtatin. Tw cranes shuld be used t rtate elements, where reasnably practicable. There is significant risk if nly ne crane is used. When a precast cncrete element is lifted flat and then tilted t a vertical psitin in ne peratin, it shuld be lifted using tw crane hks with suitable lifting eyes, as psitined by a cmpetent persn respnsible fr the erectin design. One r mre cmpetent persn/s need t be invlved t ensure that the fllwing requirements are met: The crane shuld be fitted with multiple hist drums that have autmatically applied brakes and independent winch cntrls. The crane shuld have a Lad Mment Indicatr (LMI) system that can indicate the lad n each hk being used. Page 114

115 The lifting and tailing winch and hks shuld have sufficient capacity t rtate the panel; ften the tailing lad can be up t 80% f the panel weight. The bm head n the crane shuld be suitable fr the tw hk peratin. The panels t be rtated shuld be in line with the crane t prevent: panels swinging (like a gate) when being lifted frm the panel frame the hist rpe being pulled ff the head sheave (if the fleet angle is wrng). Any lift plan needs t address the significant hazard f the panel either sliding frward r back twards the crane when it is being lifted. The bm has t be placed directly ver the centre f gravity f the panel and bm angle needs t be adjust ted t cmpensate fr bm deflectin. The included angle between the main hist rpe and the auxiliary hist rpe shuld nt exceed 30 degrees. Page 115

116 APPENDICES APPENDIX A: STANDARDS AND OTHER TECHNICAL REFERENCES THAT MAY BE APPLICABLE TO PRECAST CONCRETE WORK Applicable New Zealand and Australian standards may include, but are nt limited t, the fllwing: NZS 3101 Series NZS 3104 NZS 3112 series NZS 3109 NZS 3404 Series AS/NZS 1170 Series AS 3850 AS 4991 Cncrete structures standard Specificatin fr cncrete prductin Methds f test fr cncrete Cncrete cnstructin Steel Structures Standard Structural design actins Tilt-up cncrete cnstructin Lifting devices Technical References VDI/BV-6205 series: 2012 Lifting Anchr and Lifting Anchr Systems fr Cncrete Cmpnents (Kblenz, Germany: Bundesverband Bausysteme e.v) CEN TR Design and use f inserts fr lifting and handling f precast cncrete elements Page 116

117 APPENDIX B: GLOSSARY A-frame Anchr Base restraint Brace An A-frame trailer is designed t carry precast cncrete panels in an upright psitin. Panels usually lean and are secured t an A-shaped frame. A prprietary cast-in item r pst-installed fixing fr temprary use in the handling, transprt r erectin prcess; includes chemical anchring systems. A pstinstalled fixing is als knwn as an Alternative Lifting Device. See als Lifting insert. A restraint that stps a panel kicking in, r ut, during the erectin prcess. A structural member, nrmally placed diagnally and firmly attached t resist hrizntal mvement and prvide stability. Cmmnly used as temprary members t resist lateral lads n elements. In these guidelines, brace refers t a diagnal r nnvertical member and prp refers t a vertical member resisting a vertical lad. Chartered Prfessinal Engineer A persn is a Chartered Prfessinal Engineer (CPEng) if they are registered and hld a current registratin certificate. See fr mre infrmatin. Cmpetent persn Cntract drawings CPEng Crane In these guidelines, a cmpetent persn is smene wh has the relevant knwledge, experience and skill t carry ut a particular task using apprpriate techniques and prcedures; and: has a relevant qualificatin prving that they have the knwledge, experience, and skill required; r their emplyer has evidence (such as training recrds) demnstrating that the persn has the required knwledge, experience, and skill. see Drawings see Chartered Prfessinal Engineer A pwered device equipped with mechanical means fr raising r lwering lads suspended by means f a hk r ther lad-handling device; and that can, by the mvement f the whle device r f its bm, jib, trlley r ther such part, repsitin r mve suspended lads bth vertically and hrizntally; and includes all parts f the crane dwn t and including the hk r ladhandling device, and all chains, rails, rpes, wires, r ther devices used t mve the hk r lad-handling Page 117

118 device; but des nt include lifting gear that is nt an integral part f the crane. Crane platfrm The flr slab, suspended slab, structure r grund and surrunding area that is required t supprt a crane and its lifted lad. Crush zne Cyclic lad Deadman Designer Dgman An area where a persn culd be crushed between a transprted precast element and a slid bject. A recurring lad, r a recurring reversing lad. see In-grund mass blcks A persn wh is qualified because f their training and experience t design a device, system r element t serve a specific purpse. A persn respnsible fr the safe rigging and mvement f a lad, wh knws hw t use the crrect sling and understands the crane they are wrking with. A dgman is cmpetent t d elementary slinging r lifting tasks and direct psitin lads. (See als Rigger.) Drawings a) Shp drawings: detailed drawings f individual precast cncrete elements, prduced slely fr the manufacture f thse elements. b) Cntract drawings: drawings frming part f the cntract between the principal r wner and the head cntractr, including structural drawings, architectural drawings, and ther drawings. c) Structural drawings: drawings supplied by an engineer in supprt f a building cnsent applicatin and frming part f the cntract drawings. d) Other drawings: may include varius temprary wrks drawings that culd cver, amngst ther items, things such as bracing, prpping, lcatin and arrangement f the elements in their final lcatin. There culd be a whle range f ther drawings used n a cnstructin prject. The drawings will vary depending n the circumstances. Drp zne Dunnage Element The area where a precast element wuld land fllwing an uncntrlled fall. Fr example, during lifting r placing by a crane. Timber r ther material used under r between precast cncrete elements t prevent damage r instability during strage and transprtatin, r t allw access fr unlading r handling. see Precast cncrete element Page 118

119 Engineer wh is a CPEng A Chartered Prfessinal Engineer registered under the Chartered Prfessinal Engineers f New Zealand Act 2002 and hlding a current registratin certificate. Engineered Lift Plan Exclusin Zne Expansin anchrs Factr f Safety Falsewrk Fting Fundatin Hazard A plan fr cmplex lifts. May fllw a similar frmat t a Lift Plan, but will generally have mre detailed/technical cntent. Usually develped by an engineer r similarly cmpetent persn. A defined area where peple are nt allwed t g when particular wrk is being dne. Pst-installed anchrs, knwn as heavy duty high lad slip expansin anchrs r lad-cntrlled anchrs, where an increase in lad results in increased wedging frce. The rati between the minimum breaking lad and the wrking lad limit. The temprary structures and/r systems used t supprt a permanent structure during erectin and until it becmes self-supprting. Falsewrk is a part f temprary wrks. See Temprary Wrks see Fundatin The fundatin cnnects a structure (eg a building) t the grund and transfers lads frm the structure t the grund. Fundatins include ftings. A fting sits under the base f a wall r clumn and distributes the lad. Behaviur that has the ptential t cause death, injury r illness - whether r nt that behaviur results frm physical r mental fatigue, drugs, alchl, traumatic shck r anther temprary cnditin that affects behaviur. Health and Safety Cmmittee (HSC) Health and Safety Representative (HSR) A cmmittee enabling businesses and wrker representatives t meet regularly and wrk cperatively t imprve health and safety at wrk. HSCs bring tgether wrkers and management t develp and review health and safety plicies and practices fr the wrkplace. HSCs make it easier fr the business and wrkers t c-perate n ways t ensure wrkers health and safety. A wrker elected t represent the members f their wrk grup n health and safety matters. HSRs play an imprtant rle in keeping wrkplaces healthy and safe. They prvide a vice fr wrkers wh might nt Page 119

120 therwise speak up. By representing wrkers, HSRs prvide a link between wrkers and management. HSRs have legally defined functins and pwers. After cmpleting the NZQA unit standard 29315, an HSR has the pwer t issue a Prvisinal Imprvement Ntice (PIN) and can direct unsafe wrk t cease. In-grund mass blck In situ cncrete Lateral bracing Levelling shims Lift plan Lifting beam Lifting clutch Lifting equipment Lifting insert Lifting spreader Lad restraint A specifically designed cncrete blck that supprts the base f the brace. Lateral lads are resisted by the mass f the cncrete blck and the frictin between the cncrete surface and the supprting grund. Cncrete that is cast in its final psitin (rather thanbeing cast in ne place and then later mved t anther psitin). see Base restraint Either a single thin strip r a series f thin strips f a suitable material placed under precast cncrete elements t help with final psitining. A dcument that details hw t carry ut simple r regular crane lifts. Usually develped by the lift team r similarly cmpetent peple. May be used as an additin t, r as an alternative t, Jb Safety Analysis (JSA). See als Engineered Lift Plan. A beam that carries lads using tw r mre lifting pints while being supprted frm ne r mre different pints. A device that cnnects directly t the cast-in lifting insert t enable attachment t and transfer f lad t a crane, r ther lifting r handling equipment. Equipment that cnnects a precast cncrete element t a crane r ther lifting device. (Des nt include anything that is an integral part f a crane r ther lifting device r is cast int the precast cncrete element.) A cmpnent cast int a precast cncrete element t prvide a pint f attachment fr the lifting equipment. A cmpressin member that spreads lifting rpes, chains r slings while an element is being lifted t change the angle f the frce applied t the lifting inserts. Lashings, baulking arrangements (eg chcks) and lad frictin that prevent mvement f a lad during transprt. See the New Zealand Transprt Agency s The Official New Zealand Truck Lading Cde. Page 120

121 Nn-standard lift PCBU A lift that requires specific rigging r lad equalisatin prcedures t ensure a lad is distributed apprpriately t the lifting pints. Any lift requiring attachment t mre than tw lifting pints in a beam, r three lifting pints fr a face-lifted element, will nrmally be a nnstandard lift. Persn cnducting a business r undertaking. In mst cases a PCBU will be a business entity, such as a cmpany. Hwever, an individual carrying ut business as a sle trader r self-emplyed persn is als a PCBU. A PCBU des nt include wrkers r fficers f a PCBU, vlunteer assciatins with n emplyees, r hme ccupiers that emply r engage a tradespersn t carry ut residential wrk. Plant Precast cncrete Includes: a) any machinery, vehicle, vessel, aircraft, equipment (including persnal prtective equipment), appliance, cntainer, implement, r tl; and b) any cmpnent f any f thse things; and c) anything fitted r cnnected t any f thse things. A cncrete element cast in ther than its final psitin (see In situ cncrete). Precast cncrete element Any item f precast cncrete (such as a precast beam, clumn, flr slab, wall panel, cladding panel, pile, pile cap, r crucifrm). Prp Rebar Reinfrcing steel A structural member prviding temprary supprt fr a precast cncrete element. Cmmnly used t supprt flrs and beams. Within these guidelines, prp refers t a vertical member resisting a vertical lad and brace refers t a diagnal r nn-vertical member. (Nte that diagnal bracing is smetimes referred t as a panel prp.) see Reinfrcing steel Steel with a circular r practically circular crss-sectin, suitable fr reinfrcing cncrete. Als knwn as re r rebar (reinfrcing bar). Reinfrcing steel is available as bars, cils, wire strand, r mesh, depending n the applicatin. Page 121

122 Reinfrcement Refers t any f the fllwing: a) structural reinfrcement, including reinfrcing steel and pre-stressing tendns, as required by the cntract dcuments b) reinfrcement additinal t the structural reinfrcement, prvided t resist frces caused by transprt r erectin lads, and c) reinfrcement which is placed in cnjunctin with lifting, bracing and fixing inserts s that they can attain their design capacities. Re Restraint see Reinfrcing steel Generally refers t smething used t limit mvement (including buckling), but the exact meaning will depend n the cntext. Fr example: A restraint line is a sling, rpe r chain attached frm the suspended lad t the telescpic handler and the dgman/rigger, t help t prevent the suspended lad swinging back and frth. see als Lad restraint Rigger Rigging A rigger has brader respnsibilities than a dgman and may be respnsible fr wrk that a dgman is nt qualified t perfrm. A rigger is cmpetent t sling lads and direct the lifting and placing peratins f a crane. The rigger may als be cmpetent t develp r amend a lift plan. Mechanical lad-shifting equipment and assciated gear used t: a) mve, place r secure a lad including plant, equipment, r members f a building r structure b) ensure the stability f thse members c) set up and dismantle cranes and hists (ther than the setting up f a crane r hist which nly requires the psitining f external utriggers r stabilisers). Safety factr Safe wrking lad Shp drawings Site supervisr see Factr f safety The maximum lad that can be lifted by a piece f lifting equipment. see Drawings Smene at the wrkplace wh has authrity ver peratins n site. They have delegated respnsibility by the head cntractr r the persn respnsible fr the peratin and safety f the site. Page 122

123 Spalling Standard lift Strngback Structural drawings SWL Tag line Temprary wrks Tilt panel Tast rack Wrker The unintentinal shearing ff f a part f the precast cncrete element (eg arund lifting inserts). Nrmally due t a cncentratin f lad r t sliding. A lift that requires n special rigging r lad equalisatin prcedures. Generally nt mre than tw anchrs shuld be capable f carrying the applied lad with the required factr f safety fr a beam, r three anchrs fr a facelifted element. A device, beam r girder temprarily fixed t a precast cncrete element t give it extra strength r supprt during handling, transprt r erectin. see Drawings see Safe wrking lad A rpe used t cntrl the lad during lifting r psitining. The rpe needs t be f suitable strength, cnstructin and length. Temprary facilities (such as fencing, site ffices and wrkers facilities), and bjects such as scafflding, safety barriers and falsewrk, that are required n site nly until the permanent wrks are cmpleted. A cncrete element, nrmally cast hrizntally at r near its final lcatin. It is ften lifted t the vertical with ne edge staying n the casting flr. A stand shaped like a tast rack, used fr upright strage f precast cncrete panels. Tast racks shuld be designed and installed by a cmpetent persn wh specifies the rack capacity and prcedures fr its use. An individual wh carries ut wrk in any capacity fr a PCBU. The term wrker cvers almst all wrking relatinships. A wrker may be an emplyee, a cntractr r sub-cntractr, an apprentice r trainee, an utwrker, a persn n wrk experience r a wrk trial, r a vlunteer wrker. Wrking lad/wrking lad limit see Safe wrking lad Page 123

124 APPENDIX C: HEALTH AND SAFETY MANAGEMENT SYSTEM (HSMS) An effective health and safety management system (HSMS) will help a cnstructin site perate safely, by ensuring efficient ways f dealing with risks that can cause harm t wrkers r thers, and by identifying and cntrlling thse risks. An HSMS brings tgether plicies and prcedures t create a systematic apprach fr managing health and safety in a precast cncrete peratin, and shuld be part f the peratin s verall management system. The size and cmplexity f the precast cncrete peratin will determine hw detailed the HSMS shuld be. PCBUs prduce, dcument and maintain a HSMS, and share it with wrkers. The HSMS shuld be available t all wrkers in ne r mre frmats that are easy fr wrkers t access and understand. Review the HSMS peridically and make sure it is available fr WrkSafe t inspect, if requested. HSMS: WHAT TO CHECK Des the HSMS include: the site s health and safety plicy? prcesses fr identifying hazards, assessing risks and identifying cntrl measures t manage risks? the systems and prcedures in place t identify changes t the peratin r changes t risk levels? prcesses fr mnitring, assessing and inspecting wrkplaces? prcesses fr mnitring wrkers health and safety? prcesses and plans fr incident investigatins? prcesses fr mnitring and auditing the HSMS (that is, hw the HSMS will be reviewed and audited)? rganisatinal structure, respnsibilities and cmpetencies? prcesses fr reprting and recrding health and safety infrmatin, including key perfrmance indicatrs? Page 124

125 APPENDIX D: HEALTH AND SAFETY REPRESENTATIVES, AND HEALTH AND SAFETY COMMITTEES HEALTH AND SAFETY REPRESENTATIVES A Health and Safety Representative (HSR) is a wrker elected t represent the members f their wrk grup n health and safety matters. HSRs play an imprtant rle in keeping wrkplaces healthy and safe. They prvide a vice fr wrkers wh might nt therwise speak up. By representing wrkers, HSRs prvide a link between wrkers and management. Figure 18 summarises a PCBU s wrker engagement and participatin duties. A PCBU must engage with its wrkers when electing an HSR and/r establishing an HSC. HSRs have legally defined functins and pwers t imprve health and safety in the wrkplace. HSRs have these functins and pwers after they have been elected (r are regarded as having been elected) by fellw wrkers in their wrk grup. After cmpleting initial training, trained HSRs have the pwer t: issue a Prvisinal Imprvement Ntice (PIN). A PIN is a written ntice issued t a persn, telling them t address a wrk health and safety matter that breaks the law direct wrkers t cease unsafe wrk where there is a serius risk t health and safety frm an imminent r immediate expsure t a hazard. Any wrker can ask fr an HSR and any business can chse t have an HSR. There are sme businesses that must arrange an electin fr an HSR if asked. HEALTH AND SAFETY COMMITTEES Health and Safety Cmmittees (HSCs) supprt the nging imprvement f health and safety acrss the whle wrkfrce. They: enable businesses and wrker representatives t meet regularly and wrk cperatively t imprve health and safety at wrk bring tgether wrkers and management t develp and review health and safety plicies and practices fr the wrkplace make it easier fr the business and wrkers t c-perate n ways t ensure wrkers health and safety. Fr mre infrmatin WrkSafe s interpretive guidelines Wrker Representatin thrugh Health and Safety Representatives and Health and Safety Cmmittees WrkSafe s gd practice guidelines Wrker Engagement, Participatin and Representatin Page 125

126 WrkSafe s pamphlets: Wrker Representatin Health and Safety Cmmittees Health and Safety Representatives Page 126

127 effective wrker participatin is vital t managing health and safety issues successfully in the wrkplace. 5 The best results are achieved when a PCBU and its wrkers wrk tgether t manage risk, imprve health and safety at wrk, and find slutins. Figure 18: Wrker engagement, participatin and representatin at a glance 5 The Reprt f the Independent Taskfrce n Wrkplace Health & Safety: He Krwai Whakaruruhau (2013) Page 127

128 APPENDIX E: JOB SAFETY ANALYSIS TEMPLATE Jb Safety Analysis wrksheet (JSA) Dcumenting yur chsen cntrl measures can assist with planning wrk that is healthy and safe fr wrkers and thers. Jb N Jb descriptin Date Prepared by (name and title) Apprved by (name and title) All JSA team members: print name and sign belw t cnfirm that yu have read, understd and agreed t the prcedures and cntrl measures in this JSA. Name Name Name Signature Signature Signature Name Name Name Signature Signature Signature Are wrk permits required? Y/ N If yes, prvide details. Ntes Page 128

129 Jb Safety Analysis wrksheet (JSA) Fr each step f a jb, identify the hazards, risks t deal with, pririty, and cntrl measure/s. Jb step Jb step hazard Identify risks yu need t deal with (ptential harm frm hazard) Pririty/Urgency Pay clse attentin t yur high pririty risks CONTROL MEASURE First try t eliminate risk CONTROL MEASURE If eliminatin nt pssible: Substitutin, Islatin, Engineering if pssible CONTROL MEASURE Then if any risk still remains: Administrative cntrls, r PPE (PPE is least effective; shuld nt be first r nly cntrl measure cnsidered.) Page 129

130 Identify plant, equipment and tls required fr healthy and safe wrk fr this jb Identify wrker skills training and/r supervisin required fr healthy and safe wrk fr this jb Fr further infrmatin, refer t: 1. Material Safety Data Sheets 2. HSWA and relevant regulatins 3. WrkSafe resurces such as Cdes f Practice and guidelines (see 4. Industry-specific guidance 5. Permit attachments Page 130

131 APPENDIX F: NOTIFICATIONS TO WORKSAFE Ntificatin f particular hazardus wrk PCBUs (including persns wh cntrl the wrkplace) must ntify WrkSafe at least 24 hurs befre ding any hazardus wrk (as defined belw). These ntices help WrkSafe plan wrkplace visits t prmte health and safety fr everyne in r near a wrkplace. Ntify WrkSafe by: filing a Ntificatin f Particular Hazardus Wrk nline at r phning Wrk that needs t be ntified t WrkSafe Wrk that needs t be ntified t WrkSafe is defined in the HSE Regulatins as: any cmmercial lgging r tree-felling any cnstructin wrk where: wrkers culd fall 5 m r mre (excluding wrk n a huse up t tw streys high, a pwer r telephne line, r carried ut frm a ladder nly, r minr r rutine maintenance r repair wrk) scafflding frm which smene culd fall 5 m r mre while the scafflding is being put up r dismantled an appliance (ther than a self-prpelled mbile crane, excavatr r frklift) has t lift weights f half a tnne (500 kg) r mre higher than 5 m wrkers have t wrk in a pit, shaft, trench r ther excavatin that is mre than 1.5 m deep and which is deeper than it is wide at the tp wrkers need t wrk undergrund in any kind f excavatin, heading r drive, where there is grund cver verhead in any excavatin in which any face has a vertical height f mre than 5 m and an average slpe steeper than a rati f 1 hrizntal t 2 vertical explsives are used, r stred n site fr this purpse wrkers need t breathe air that is r has been cmpressed r breathe a respiratry medium ther than air. (There is an exceptin in regulatin 26(4), HSE Regulatins). Page 131

132 Ntifiable events A ntifiable event is any f the fllwing events that arise frm wrk: a death a ntifiable illness r injury a ntifiable incident. WrkSafe must be ntified when ntifiable events ccur. These events trigger requirements such as preserving the site and keeping recrds. The ntifiable incident, illness, injury r death must arise ut f the cnduct f the business r undertaking. It culd be due t the cnditin f the wrk site, the way the wrk activity is rganised, r the way equipment r substances are used. Ntifiable events may ccur inside r utside the actual wrk site. A ntifiable illness is when smene becmes seriusly ill as a result f wrk; this is then a ntifiable event. All wrk-related injuries r illnesses which require a persn t be admitted t hspital fr immediate treatment are ntifiable. See Sectin 23 f HSWA fr the full meaning f ntifiable injury f illness and a list f injuries and illnesses that require ntificatin. Ntifiable incidents HSWA requires PCBUs t ntify WrkSafe if there is an unplanned r uncntrlled incident in relatin t a wrkplace that expses a persn (wrker r therwise) t a serius risk t their health and safety because f immediate r imminent expsure t: a substance escaping, spilling, r leaking an implsin, explsin r fire gas r steam escaping pressurised substance escaping electric shck the fall r release frm height f any plant, substance r thing damage t r cllapsing, verturning, failing r malfunctining f any plant that is required t be authrised fr use the cllapse r partial cllapse f a structure the cllapse r failure f an excavatin r any shring supprting an excavatin the inrush f water, mud, r gas in wrkings in an undergrund excavatin r tunnel the interruptin f the main system f ventilatin in an undergrund excavatin r tunnel a cllisin between tw vessels, a vessel capsize, r the inrush f water int a vessel any ther incident declared in regulatin t be a ntifiable incident. Page 132

133 Fr mre infrmatin Sectin 23 f HSWA WrkSafe s fact sheet What events need t be ntified? WrkSafe s website fr nline tls, frms and ther resurces Page 133

134 APPENDIX G: DUTIES OF DESIGNERS, MANUFACTURERS, IMPORTERS, SUPPLIERS, INSTALLERS, CONSTRUCTORS AND COMMISSIONERS PCBUs wh are designers, manufacturers, imprters r suppliers must, s far as is reasnably practicable, make sure that the plant, substances, and structures designed, manufactured, imprted r supplied (as relevant) are withut health and safety risks when they are used, r culd reasnably be expected t be used, in a wrkplace. Imprters must ensure imprted gds meet all New Zealand regulatry requirements. PCBU installers, cnstructrs and cmmissiners f plant and structures must, s far as is reasnably practicable, make sure that the way that the plant r structure is installed, cnstructed r cmmissined is withut health and safety risks t the peple listed in Table 4, belw. The table summarises the duties f these PCBUs, based n Sectins f HSWA. These duties d nt apply t the sale (by suppliers) f secnd-hand plant sld as is. Page 134

135 Table 4: Overview f duties f PCBU designers, manufacturers, imprters, suppliers, installers, cnstructrs and cmmissiners Page 135