How Precast Concrete Improves On-Site Safety

  • Safety
6 min read
How Precast Concrete Improves On-Site Safety

The Work Health and Safety (WHS) ensures all employers in all industries in Australia implement risk management processes in their workplaces. WHS ensures strict safety requirements in the construction industry, specifically for projects using precast concrete elements, considering high-risk work activities, safety hazards, and strategies to control these risks.

Using precast concrete ensures safety in construction projects. Precast elements are safer than cast-in-place concrete because of their superior quality and durability, greatly reducing on-site hazards. Precast concrete is manufactured in a controlled factory, ensuring consistent quality, following WHS standards.

Learn more about precast concrete and how it’s safer for construction projects than cast-in- place components.

The Problem with Traditional Concrete Construction

Erecting concrete structures used to rely only on traditional methods. Concrete is poured into a wooden or metal frame called formwork. These concrete components are given time to cure and dry on-site, relying on good weather for the best results.

This method may seem practical, but it poses several issues. They include:

On-site pouring

Traditionally, concrete is mixed and poured in a formwork; thus, the construction area must have enough space and equipment to prepare and pour the concrete. Most of the time, this is done by workers by hand.

Excessive manual labour

Workers mix and pour concrete by hand. They also finish concrete surfaces by hand, which leads to varying results. Excessive manual work leads to injuries, exhaustion, and dehydration, especially when working during hot conditions.

Formwork and scaffolding

These are critical for shaping and supporting concrete components. If not properly installed, inspected, and maintained, these can lead to safety risks such as falls and crushing injuries.

Curing delays

Concrete takes around 28 days to cure to ensure good strength and durability. Delays can lead to cracking and stability issues. Poor weather conditions, inadequate protection, and insufficient moisture can impact curing.

How Precast Construction Reduces WHS Risks

1. Reduces on-site labour needs

Precast concrete is manufactured off-site in a controlled environment. It arrives ready for assembly or integration with the project. Thus, there is reduced need for on-site labour with workers mostly focusing on the assembly of the structure rather than tedious mixing, pouring, and formwork.

2. Eliminates on-site curing and formwork setup

Precast concrete elements are cured off-site, so there’s no need to wait longer for concrete to cure and dry, eliminating project delays. There’s also no need for detailed formwork tasks, so workers can concentrate their time and expertise in other areas of the construction project.

3. Minimise time spent working at heights

Pouring concrete and formwork requires workers to work in elevated areas, which increases WHS risks. Meanwhile, precast concrete will be ready for installation once it arrives on site, with workers mostly focusing on assembling the concrete components.

4. Controlled lifting with rigging and crane plans

Precast concrete transport, lifting, and assembly calls for appropriate, specialised equipment such as rigs and cranes. WHS requires detailed rigging and crane plans to ensure safety and efficiency during the lifting of concrete elements

Safety Benefits of Factory-Controlled Production

Precast concrete is manufactured in a controlled environment under strict safety standards.

Use of correct concrete mixes

Precast concrete manufacturers ensure correct concrete mixes and the right amount of moisture for the best results. The proper concrete mix is critical for achieving the desired strength, durability, and workability. It comprises cement, the binding agent, aggregates, water, and admixtures or additives to enhance setting time, air content, and workability.

Creating the formwork

A precise formwork is essential for achieving the desired shape, dimensions, and features, including slabs, beams, and walls. Formwork is typically made from plywood or steel to hold the poured concrete as it cures. Once the formwork is ready, mixed concrete is poured and left to cure. Curing takes up to 28 days, and at this time, the precast material achieves its full strength.

Strict quality inspections

Precast concrete is meticulously inspected for quality and compliance. Checks include material certifications, manufacturing processes, and the quality of the final product. Inspections also include verifying the accuracy of dimensions, strength tests, and checks for surface defects.

Automated production ensures consistent quality.

Modern precast concrete factories use automated equipment to manufacture precast elements with consistent quality. Key pieces of equipment in these factories include shuttering/deshuttering robots, automated concrete pouring systems, and handling and reinforcement machines.

Trained factory staff

Despite automated equipment, trained staff are vital for operating and maintaining machinery, ensuring quality control, and managing the production process. Staff also handle tasks that may be too complicated to automate, such as reinforcing concrete and finishing precast surfaces.

Less Rework = Fewer On-Site Hazards

Precision-manufactured precast concrete elements reduce on-site issues by reducing misalignment issues, delays, and the need for immediate, on-site problem solving.

Factory-made precast components are preformed and designed with precision, which leads to faster and more accurate assembly, reducing the likelihood of on-site errors.

  • Reduced misalignment: Precast elements are produced in controlled environments. Thus, they possess consistent dimensions and precise tolerances, avoiding misalignment issues during installation.
  • Minimises delays: Precast concrete is manufactured in a climate-controlled factory, so there’s no need to worry about weather-related delays. Also, precast components may be ordered ahead of time and delivered to the project site. This significantly reduces on- site labour and material handling, speeding up the construction timeline.

Reduced delays and errors promote a safer working environment, considering WHS requirements.

Real-World Safety Outcomes with Ozcast Precast

Ozcast Precast ensures compliance in every step of the precast concrete manufacturing process. Our components have contributed to safety and consistent WHS outcomes, significantly reducing workplace risks and promoting installation efficiency.

Our projects show our commitment to safety. One of our standouts is the Sydney Metro Viaduct project where we supplied custom precast elements developed for rapid, low-risk installations.

Using cast-in lifting points and following strict quality inspection protocols, the installation process was completed faster, ensuring fewer manual handling incidents were reported.

Another project we are proud to participate in was the Western Sydney International Airport (AeroWest) project where we tailored parapets and road components to help crews work safely.

Each Ozcast precast unit comes with clearly-marked lifting points to ensure balanced, secure handling during unloading and placement. These greatly reduce strain injuries or equipment failure on-site.

Ozcast Precast proves that smart design and careful planning go hand-in-hand with safer, more efficient outcomes. Find out how we can support your next project’s safety goals. Get in touch with our team today.

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