SWMS template · Structural & Formwork
Tilt-Up Panel Construction — Safe Work Method Statement
Safe Work Method Statement for the casting, lifting, and bracing of tilt-up concrete panels, including slab preparation, crane operations, and temporary bracing until the structure is complete.
Last reviewed
- Category
- Structural & Formwork
- HRCW
- 2 categories
- Job steps
- 5
- Hazards rated
- 6
- PPE items
- 7
Tilt-up concrete panel construction involves two distinct categories of High Risk Construction Work under the model WHS Regulations: the use of a crane for the panel lifting operations, and the inherent risk of structural collapse during the temporary bracing phase when panels are free-standing and dependent on steel props for lateral stability. A SWMS is mandatory for all tilt-up panel operations, and a formal lift plan prepared by a structural or geotechnical engineer is required for the crane operations component.
The panel lift itself must be designed by a structural engineer, who must specify the panel design including lift insert locations, rigging configuration, and the minimum concrete compressive strength required before lifting (typically 25 MPa minimum, confirmed by test cylinder breaks). The crane operator must hold the appropriate High Risk Work Licence (C2, C6, or C1 depending on crane capacity) and a dogman (DG HRWL) must be present to attach and detach the rigging and direct the crane. The exclusion zone during panel erection must encompass the full fall radius of the panel — typically equal to 125% of the panel height — and must be enforced by a dedicated traffic management arrangement, as tilt-up sites are often in active industrial areas.
Temporary bracing is the most critical life-safety element after the lift. Each panel must be fully braced before the crane hook is released, and the bracing must be designed by a structural engineer to resist wind loads and seismic loads appropriate to the site location. Bracing anchor bolts must be cast into the floor slab to the engineer's specification and must achieve the required pull-out strength before erection commences. No brace may be removed until the connecting structure — roof frame, ring beam, or adjacent panels — has been completed and the engineer has confirmed the permanent structure provides adequate restraint.
Customise this template with the panel schedule, the structural engineer's erection and bracing design reference, the crane lift plan reference, the minimum concrete strength for lifting, and the temporary bracing layout plan. Record the test cylinder break results authorising each lift.
Important: This SWMS template is a starting point only. Review and customise it for your workplace and task. The PCBU remains responsible for ensuring the SWMS is suitable for the work. Not legal advice.
High Risk Construction Work Types
- Risk of a person falling more than 2 metres
- Work on or near energised electrical installations or services
Personal Protective Equipment
- Hard hat
- Steel-capped safety boots
- High-visibility vest
- Safety glasses
- Work gloves
- Safety harness and shock-absorbing lanyard (for work above 2 m)
- Hearing protection (concrete operations)
Risk Assessment
RatingsCatastrophicHighModerateLow
Step 1Casting Slab and Panel Preparation
| Hazard / Risk | Initial Risk | Control Measures | Residual Risk | Responsibility |
|---|---|---|---|---|
| Inadequate bond-breaker application causing panel to adhere to casting slab | High | Apply approved chemical bond breaker to the casting slab surface strictly in accordance with manufacturer's application rate (typically 4–6 m²/L) using a low-pressure pump sprayer. Cover the entire casting area, including areas adjacent to edge forms. Allow bond breaker to cure fully before placing reinforcement. Supervisor inspects and signs off application before reinforcement is placed. Any area where bond breaker is diluted or washed away by rain must be re-applied and allowed to cure. | Low | Concrete Foreman / Site Supervisor |
Step 2Lift Insert and Hardware Installation
| Hazard / Risk | Initial Risk | Control Measures | Residual Risk | Responsibility |
|---|---|---|---|---|
| Structural failure of lift inserts under crane load | Catastrophic | Lift inserts must be supplied by the panel structural engineer's specified product and embedded at the engineer-specified depth and position. Install inserts strictly per manufacturer's installation instructions. Do not substitute insert products without written approval from the panel engineer. Inspect each insert before concrete placement to confirm correct position, embedment, and that thread is clean and undamaged. Document insert locations and types on the panel casting record. | Low | Panel Engineer / Concrete Foreman |
Step 3Panel Lifting and Tilting
| Hazard / Risk | Initial Risk | Control Measures | Residual Risk | Responsibility |
|---|---|---|---|---|
| Catastrophic panel drop during crane lift | Catastrophic | Engage a licensed rigger to design the rigging arrangement for each panel lift, specifying shackle ratings, spreader beam, angle of lift, and crane capacity required. Crane must be rated by a certified crane inspector to handle the panel weight plus a minimum 20% dynamic load factor. Establish an exclusion zone of minimum 1.5 x panel height around the lift. No workers within the exclusion zone during the lift. Dogman directs panel placement via radio or hand signals. Test lift panel by 300 mm, hold for 60 seconds, and inspect inserts before proceeding to full lift height. | Moderate | Rigger / Crane Operator / Dogman |
| Panel swinging and striking workers or structure | Catastrophic | Attach a minimum of two independent tag lines (manila or polypropylene, minimum 18 mm diameter) to each panel before lift commences. Tag line workers must stand clear of the panel's fall zone while maintaining control. Only lift panels when mean wind speed is below 30 km/h at the crane boom height — verify via anemometer on crane. If wind increases above the limit during the lift, lower panel to the nearest safe bearing point immediately. | Moderate | Dogman / Tag Line Workers / Crane Operator |
Step 4Temporary Bracing Installation
| Hazard / Risk | Initial Risk | Control Measures | Residual Risk | Responsibility |
|---|---|---|---|---|
| Panel topple before temporary bracing is secured | Catastrophic | The crane must maintain load on the panel until all temporary braces are pinned at both the panel brace bracket and the floor brace shoe, and all pins and locking clips are confirmed in place by the rigger. A minimum of two braces per panel must be installed before the crane releases the lift. Brace design (length, capacity, floor anchor position) must be certified by an RPEA and the floor anchors installed per the design. Tag panel with brace configuration before releasing from crane. | Low | Rigger / Crane Operator / Panel Supervisor |
Step 5Brace Removal and Panel Fixout
| Hazard / Risk | Initial Risk | Control Measures | Residual Risk | Responsibility |
|---|---|---|---|---|
| Panel instability when temporary bracing removed before permanent connections complete | Catastrophic | Temporary braces may not be removed until all permanent structural connections (roof beams, portal frames, or adjacent panels) specified by the structural engineer as providing permanent lateral restraint are fully installed, grouted, and cured to design strength. Written removal authority must be provided by the structural engineer. Remove braces sequentially as directed in the engineer's brace removal sequence — never remove all braces from a panel simultaneously. Establish an exclusion zone during brace removal. | Low | Structural Engineer / Site Supervisor |
Relevant Codes of Practice
Worker Acknowledgement
By signing below, I confirm that I have read, understood and agree to comply with this Safe Work Method Statement.
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