Concrete weighs 2,400kg per cubic metre — that’s more than three times heavier than the equivalent volume of timber (700kg). A 450x450x450 standard precast concrete pit (SVC’s smallest stock pit) weighs 280kg, which is more than enough to cause significant damage if dropped. When such heavy items are involved, customers must abide by the correct safety procedures when handling, lifting, or transporting the product.

Risks of Improper Precast Concrete Lifting Practices

Ample safety precautions are required at all times when working with heavy concrete products. Failure to use the appropriate lifting tools or techniques may lead to product failure, breakages, damage to products or machinery, or, in the worst-case scenario, accidental injury.

During transport, concrete products are typically loaded onto delivery trucks, which can have trays that are 1m to 1.5m high. Products dropped from this height are unlikely to remain intact.

Industry Regulations & Standards for Precast Concrete Lifting

There are many ways to lift precast concrete, but selecting a method should never be a case of personal preference. Instead, you should lift precast concrete following Australia’s industry standards to ensure safe handling and minimise liability. In Australia, key guidance comes from:

• AS 3850.1:2015 – Prefabricated concrete elements – Part 1: General requirements
• AS 3850.2:2015 – Prefabricated concrete elements – Part 2: Building construction
• Work Health and Safety (WHS) Regulations 2011, particularly regulations surrounding manual handling, plant operation, and lifting gear.

These standards specify everything from anchor design and load limits to handling procedures on-site. For example, lifting clutches and anchors must be used with compatible, tested components — all rated to match the working load limit (WLL). Likewise, slings and chains must undergo regular inspections and conform to AS 4497 (slings) and AS 3775 (chain slings).

At SVC, we strongly encourage all site managers and contractors to stay current with the legislation and ensure that lifting practices and equipment are fully compliant.

Appropriate Techniques for Lifting Precast Concrete

Each of the many methods for lifting heavy concrete products requires a specific type of lifting apparatus. Sometimes, more than one technique may be suitable for a particular product, and the final method is selected based on the best fit for the project. The types of lifting methods are outlined below:

Manual Lifting

When installing pavers on a residential footpath or working with lightweight civil accessories like grates and gatic lids, manual lifting may seem straightforward. While there are no legally fixed weight limits, SVC recommends a two-person lift for anything above 15kg. For example, a 20kg paver may not seem heavy initially, but repeated solo lifting over one day can quickly result in fatigue or injury. Use proper lifting techniques (back straight, knees bent, feet stable), and where possible, use handling aids like paver tongs or dollies to reduce strain and improve efficiency on-site.

On larger-scale landscaping jobs, teams that consistently use lifting aids often report smoother workflows and fewer injury-related delays. Conversely, repeated solo lifting of heavier items — even just above 15kg — can result in strains or back injuries, ultimately affecting project timelines.

Forklift Lifting

Forklifts can transport precast products, such as pits or headwalls, in controlled factory environments. Next, the precast products typically go onto standard pallets rated for up to two tonnes. To ensure stability during transit, products should be centred on the pallet and secured with straps or shrink wrap. Custom bracing may also be necessary for heavy, tall, or disproportionately weighted items.

Before lifting, forklift operators should inspect each pallet for damage, especially those made from timber. Cracked or weakened pallets can collapse during handling, especially in damp conditions. Checking that the forklift can handle the load — and that the tynes are set up to avoid tipping or shifting — is also critical. This method is efficient for repeatable loading tasks but should always follow safe operating procedures and align with relevant Australian Standards, such as AS 2359 for powered industrial trucks.

Lifting Hooks

When transporting SVC precast concrete pits with lifting holes marked ‘Lift Here Only,’ it’s critical to use the approved 2.0-tonne lifting hooks. These hooks ensure compatibility and safety. A typical scenario involves using two hooks per pit to lift as much as 2.0 tonnes, with each hook connected to a lifting chain. The chains go into the pit’s lifting holes, with the other ends attached to a central lifting point.

If the internal angle between the chains exceeds 60°, there’s a risk that the load will be distributed unevenly, which can cause the pit to tip or become unstable. Another common issue can be when hooks are inserted outside the pit or pushed too far inside, creating load points in the incorrect areas. This error can damage the pit, delay the project, and necessitate costly replacements. Always align hooks vertically from the inside of the pit to prevent these issues, ensuring the corners remain free of pressure.

SwiftLift™ Clutches & Anchors

The most common lifting method across SVC’s suite of products involves the use of SwiftLift™ lifting clutches and anchors. SwiftLift™ anchors are cast into concrete products during production, allowing flexible positioning of lifting points within a product. They are available in different sizes to suit load ratings ranging from 1.3t up to 10.0t, making them a versatile lifting tool for nearly every product.

On a busy construction site, workers frequently use SwiftLift™ clutches to lift large precast slabs, each weighing several tonnes. A crane is positioned centrally, and the chains are strung from a central lifting point to maintain the correct angle. For example, workers must carefully monitor the internal angle between the chains when lifting a large wall panel to make sure it remains below the 60° limit. Exceeding this angle could lead to an unstable lift, posing safety risks and potentially damaging the product.

In a typical scenario, the load could distribute unevenly if the angle between the chains exceeds 60°, leaving you with an unstable lift. Such a configuration can lead to tipping, which might cause delays and potentially damage the product — so it’s important to check angles while lifting. Another possible scenario involves improperly positioning the anchors. If the anchors are inserted too far inside or outside the precast element, it could create pressure points, causing cracks or compromising the integrity of the product during lifting.

The SwiftLift™ clutches are attached to the precast elements’ anchors, with the tabs pointing toward the lift. This positioning ensures the load event is distributed across the anchors, minimising stress and providing a secure lift. For more information about the use of SwiftLift™ devices, please refer to the Reid website.

Clamp Lifting

Certain products, such as concrete sleepers and kerb units, are commonly lifted using heavy-duty clamping devices. These clamps are handy on sites with limited access, where space for a crane is restricted. They allow precise and safe lifting of concrete in tight areas, such as urban environments with narrow pathways or congested workspaces. The clamps help move products efficiently without the need for large machinery.

The clamps are padded with rubber to prevent markings or damage to the product’s surface, as well as keep it intact. The clamp is connected to a crane hook via a chain when lifting. Gravity helps increase the clamp’s grip on the product, securing it in place.

Inspecting the clamp before use is crucial to ensure it’s fully engaged and debris-free, especially in wet or muddy conditions. Failure to perform this check can compromise the lift’s safety and effectiveness. For example, debris in the clamp can cause slippage, leading to an unstable lift. In one hypothetical scenario, neglecting to clear debris might result in the sleeper not being secured properly, causing potential damage to the product or the surrounding infrastructure.

Ensuring the clamp is clean and fully engaged can significantly reduce the risk of these issues, contributing to a safer and more efficient operation.

Vacuum Lifting

Vacuum lifters use strong suction forces via vacuum pads to lift heavy products with mostly flat surfaces, such as large-format pavers and concrete slabs. They’re ideal for products under 500kg and come in various formats — from handheld units to large lifting beds mounted on cranes.

One of the most significant advantages is that vacuum lifters allow for ‘invisible’ lifting, meaning no embedded lifting points are required. Invisible lifting is beneficial for precast items with decorative or architectural finishes — for example, a polished concrete slab designed for a public plaza — where visible lifting anchors compromise the finish.

To ensure a stable lift, the vacuum lifter must be positioned precisely at the centre of the product for even weight distribution. Hypothetically, if the suction pad is slightly off-centre, the slab could tilt, placing uneven pressure on the pad and increasing the risk of failure.

Environmental conditions can also affect performance. For example, surface debris may prevent the vacuum pad from sealing properly on dusty or wet construction sites. In these cases, cleaning the product surface beforehand is essential — skipping this step could result in suction loss mid-lift, which poses a serious safety risk.

Sling Lifting

Lifting slings made from durable polyester webbing are rated for loads between 2.0t and 10t. Depending on the application, slings can be in a choke or cradle configuration. In a choke sling method, the sling wraps around the product and passes through itself before being connected to a crane hook at a central lift point. This configuration can be effective for smaller cylindrical or tapered units. In contrast, the cradle sling method uses two or more slings passed beneath the product and lifted evenly. For stability, a spreader bar is best for maintaining sling separation and balancing the load.

For some custom precast items, sling recesses can be built into the design to help maintain sling position and reduce the risk of slippage. In scenarios where toppling or lateral shifting is a concern, such as lifting long or narrow items, these recesses provide additional safety.

However, it’s important to note that some sites restrict the use of sling lifting due to perceived safety concerns or site-specific policies. Contractors must always confirm whether slings are permitted and ensure that the chosen lifting method suits the available product, conditions, and access.

Chain Lifting

Construction site workers have long used chains to lift and transport precast concrete and civil products. Like slings, chains can have a choke or cradle hold, depending on the product’s shape and the lift requirements. A range of chain sizes and configurations is available, with load ratings suited to most lifting applications.

Despite their long history, chains are generally not recommended for products with aesthetic finishes. When used without proper padding, chain links can leave scuff marks, edge damage, or surface abrasions, especially on exposed or polished concrete. These risks are greater when chains go to sharp corners or uneven products.

SVC recommends lifting slings instead of chains, particularly for architectural or decorative products. Slings provide a gentler, more forgiving contact surface, reducing the risk of cosmetic damage. On sites where chains are permitted, taking precautions (such as using corner protectors or padding) can help mitigate potential issues, but this is not always sufficient, especially if a less experienced crew is managing the lift.

Spreader Bar

Spreader bars are instrumental to lifting applications where the internal angle between lifting chains would otherwise exceed 60°, which could compromise load stability or overstress lifting points. In such scenarios, a spreader bar allows chains to remain vertically aligned, ensuring safer load distribution. Spreader bars range from lightweight aluminium models for smaller architectural pieces to heavy-duty steel spreaders for multi-ton structural elements. Bars should include visible rating labels, and adjustable spreaders can be helpful for non-standard load widths.

To function correctly, chains must be attached to the spreader bar with a minimum length of 600mm and aligned vertically with the product’s lifting anchors. Unequal chain lengths or off-centre positioning can result in uneven tension, increasing the risk of swinging or tipping during the lift.

Spreader bars are handy for lifting long, narrow, or oversized products (such as large pits, beams, or culverts) where standard lifting angles are not feasible. Ensuring that the spreader bar’s overhang is equal on both sides helps prevent imbalance, which can affect both the safety of the lift and the integrity of the product.

How to Conceal Redundant Lifting Points on Precast Concrete Post-Installation

Products installed above ground in a landscape or architectural application, such as SwiftLift™ anchors, may have in-built lifting points in a visibly noticeable area. As these are no longer required post-install, some customers use various methods to conceal the lifting points.

Concrete Infill

One option is to ‘patch up’ the lifting point by infilling it with concrete. This is generally not advised as the best option, as it is always quite apparent that some patchwork has been completed. Often, the colour of the infilled concrete does not precisely match the rest of the product.

Stainless Steel Caps

Certain products, such as small stainless steel caps, can be inserted over lifting anchors. These provide a subtle additional feature that is still noticeable when looking at the product, but hides the lifting anchor.

Separate Design Elements

Most commonly, lifting points can be concealed by other material components of the product design, which are installed later, after the concrete product has been placed on-site. An example is a concrete bench with lifting points on the top, which become hidden from view by installing a timber seating frame above the concrete.

Critical: Preplanning Your Precast Concrete Handling & Lifting Techniques

Lifting considerations should not be treated as an afterthought. Product handling and transport should be considered early, especially for custom or non-conventional products. While creating workshop drawings for the approval of custom products, SVC’s drafting team will include lifting points in areas of the product we deem most logical and practical for delivery. Customers who wish to use a particular lifting technique or make specific requests regarding lifting points should communicate this during the design development stage.

As a rule of thumb, it is the customer’s responsibility to be aware of any lifting restrictions, issues regarding site access, or any other considerations that may affect the delivery of products.

Key Considerations When Selecting a Precast Concrete Lifting Technique

Generally, a product’s weight indicates the methodology for transporting it. However, weight is not the only influencing factor. Various other factors, such as product shape, site conditions, access points, and the type of lifting gear available, all contribute to deciding which lifting methods and devices will be most appropriate.

For example, oddly shaped or unevenly weighted objects may not be transportable via a forklift. Certain products may need to be loaded onto the delivery truck a certain way or into a specific position. Customers should also consider whether there is suitable access and stable ground conditions on-site to allow for the heavy machinery and equipment required for delivery.

FAQs

What Safety Precautions Should I Take When Lifting Precast Concrete?

Always inspect and tag all lifting equipment regularly, and ensure operators are trained and following safe lifting practices. Never stand under a suspended load; use guide ropes to keep a safe distance. Follow proper lifting techniques, use the right gear for the job, and check that ground conditions and access points are suitable before lifting begins.

Where Can I Purchase or Rent the Appropriate Lifting Equipment for Precast Concrete?

You can purchase or hire lifting equipment — such as lifting clutches, chains, spreader bars, and cranes — from specialised lifting and rigging suppliers, construction equipment hire companies, or through precast concrete manufacturers who may recommend trusted providers. Always ensure the equipment meets Australian Standards and is rated for the load you intend to lift.

What Are the Weight Limitations for Manual Lifting of Precast Concrete?

In Australia, there are no legally fixed weight limits for manual lifting, including for precast concrete. However, Safe Work Australia advises that loads over 15kg can pose a risk, especially if lifted repeatedly or awkwardly. Employers should assess each situation and implement controls to minimise manual handling risks — this could include team lifts, mechanical aids, or redesigning tasks to avoid lifting altogether.

Common Misconceptions About Lifting Precast Concrete

Myth 1: “If the Product Fits the Weight Limit, It’s Safe to Lift It with Any Method”

Fact: Weight isn’t the only consideration. Product shape, centre of gravity, and surface condition affect which lifting method you should choose for the job. For example, an uneven or polished surface may make vacuum lifting unsafe even if the product is within the rated capacity.

Myth 2: “Chains & Slings Can Be Used Interchangeably”

Fact: While both can lift heavy products, chains are more abrasive and can damage architectural finishes. Slings are generally safer for aesthetic or custom pieces, particularly if padded. Some sites may even prohibit chains entirely.

Myth 3: “You Can Use the Same Lifting Technique Across All Sites”

Fact: Site access, terrain, and equipment availability vary widely. A method that works on one site may be unsuitable elsewhere, especially if space is limited or ground conditions are poor.

Myth 4: “Vacuum Lifters Work on All Flat Surfaces”

Fact: They require clean, dry, and even surfaces to maintain proper suction. Wet, dusty, or porous surfaces can cause the vacuum to fail mid-lift, posing a serious hazard.

Myth 5: “If It’s a Standard Product, You Don’t Need to Think About Lifting in the Design Stage”

Fact: Every project has unique delivery and installation needs. Even with standard products, planning the lifting technique during the design and drafting phase is critical for smooth delivery and installation.

Inspecting & Maintaining Lifting Equipment

Inspecting and maintaining lifting equipment are essential tasks you should be doing frequently to ensure site safety and prevent costly accidents or equipment failure.

Routine Inspections

All lifting equipment — including slings, chains, clamps, spreader bars, and vacuum lifters — should undergo inspection before every use. Look for signs of wear such as fraying, rust, bent components, degraded pads, or missing safety features. Remove any damaged equipment from service immediately.

Regular Tagging & Testing

Per Australian safety standards, all lifting gear should be tested and tagged by a certified professional at least once every 12 months. Load testing should also occur periodically to confirm that the equipment can still handle its rated capacity.

Proper Storage

When not used, lifting gear should be stored in a clean, dry area, off the ground and away from direct sunlight or corrosive materials. Keeping equipment clean and dry extends its lifespan and reduces the risk of mechanical failure.

Training & Accountability

Only qualified personnel should inspect or operate lifting equipment. Staff must train to identify early signs of damage and understand correct storage, handling, and maintenance procedures. Assigning clear responsibility for equipment maintenance helps prevent oversights and ensures compliance with safety protocols.

Equipment-Specific Tips & Troubleshooting

Different types of lifting gear come with unique considerations:

• Slings: Inspect for cuts, abrasions, and chemical damage. If a synthetic sling shows signs of UV degradation (fading, brittleness), retire it immediately. Never knot slings to shorten them.
  
• Chains: Check for stretched links, worn spots, or improper joins. A common issue is twisting — chains must remain untwisted and straight to avoid uneven loading.
• Clamps: Ensure gripping surfaces are clean and undamaged. If a clamp slips under load, it may be due to worn pads or insufficient clamping pressure.
  
• Vacuum lifters: Test the seal and vacuum level before every use. Check for pad cracks or leaks in the hose if suction is weak. Debris on the surface being lifted can also prevent a proper seal.
  
• Spreader bars: Confirm equal overhang on both sides. If a bar leans or causes uneven lift, reassess chain length, balance, or whether the lifting points are symmetrical.

If any equipment fails inspection or performs abnormally during use, tag it out of service immediately and arrange for a qualified technician to assess, repair, or replace it.

How to Maintain Best Practice When Lifting Precast Concrete

All lifting equipment and machinery should be tested and tagged at least once a year to achieve the best results and maintain safety precautions when lifting heavy products.

Staff operating cranes or other lifting equipment should always know safe operating procedures. For example, a cardinal rule is that no individual or object should ever be directly underneath a product that is being lifted. If a staff member acting as a crane chaser/dogman needs to guide a product, a rope can be attached, allowing the crane chaser/dogman to keep a safe distance away. The crane chaser/dogman should always have a spotter who can see everything happening.

The key to ensuring a safe and smooth process during product handling and transport is for all stakeholders to be aware of their responsibilities during a project. Designers should consider lifting points, site access, restrictions, and how the final product will look on-site before deciding on their final design. Installers should also know site conditions and ensure their machinery and equipment operate safely. All staff operating cranes and other heavy machinery should be well-versed in compliance regulations and safe operating procedures.