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CROSS Safety Report

Failure of cast-in lifting eye on L-shaped wall

Report ID: 638 Published: 1 January 2018 Region: CROSS-UK

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Overview

During a routine lifting operation of a L-shaped wall unit, one of the legs on a cast-in lifting eye which was located on top of the unit pulled out of the concrete.

Key Learning Outcomes

For precast manufacturers and suppliers:

  • Quality assurance and competent supervision in the precast yard can help to ensure that precast elements are constructed in accordance with the design

  • Consider introducing a quality management procedure for the inspection of safety critical connections such as cast-in lifting anchors

  • A pre-pour and post-pour inspection of lifting anchors can help identify if they have moved or become dislodged during the pouring process

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This issue arose for the reporter during a routine lifting operation of a L-shaped wall unit. As the load was transferred through the three lifting points using chains, one of the legs on a cast-in lifting eye which was located on top of the unit pulled out of the concrete. Fortunately, the unit had not left the ground and the operation was stopped.

Figure 1 shows how the lifting eye had failed and the leg had pulled out. Figure 2 shows a sketch of the design position and the probable position of the lifting eye in the precast unit to allow the failure, according to the reporter. Following the failure of the lifting point, all lifts of the L-shaped walls ceased whilst an investigation was carried out with the supplier. The supplier attended site and inspected all units that had not already been placed. From this inspection, several further units were found to have potentially defective lifting points.

The supplier attended site and inspected all units that had not already been placed. From this inspection, several further units were found to have potentially defective lifting points

According to the reporter, the likely causes of the problem were:

  • The lifting eye was able to move within the former after closing the mould prior to casting

  • The lifting eye was disturbed with the poker whilst casting the L-shaped wall

The reporter states that the supplier has now put further quality control and inspections in place, including:

  • The way that the lifting eye is secured in the former has been amended to prevent movement during the casting process

  • Pull-out tests on the products to ensure the lifting eyes are capable of holding twice their weight

  • Additional inspection on check sheets on the L-shaped walls once cast

  • Once the units have been inspected by the supplier, all of the lifting points will be coloured to confirm they are suitable, and a tick marked on the base of the unit

Image
Figure 1: failure of cast-in lifting eye
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Figure 2: sketch of cast-in lifting eye (a) design position (b) probable cast-in position

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