Erecting Long, Vertical Precast Concrete Members With 2 Operating Lines

Erecting long,
vertical
precast
concrete
members
with one
crane and
two operating
lines
Donald R. Logan
Background
The most common procedure to erect long vertical precast
concrete members is to rotate the members in midair
from their as-delivered flat position to their final vertical
position in the structure. To keep member stresses during
lifting within acceptable limits, this procedure normally
involves supporting the member at three points. One point
is at or near the top of the member, and the two lower
reactions are supported by slings threaded through rolling
blocks, one end attached near the bottom of the member
and the other end close to its midheight (Fig. 1).
Editors quick points

n Erectors have reported incidents in which precast concrete
members have rolled uncontrollably during erection.
n PCI issued an alert regarding this phenomenon in December
2008.
n This article provides reliable methods to determine the cause
of panel instability and discusses ways to anticipate and avoid
panel instability.
118
W int e r 2 0 1 0 | PCI Journal
Erectors have reported incidents that occurred while using

this common erection procedure in which precast concrete
members suddenly rolled from an apparently stable tilt
angle to the vertical position. These incidents often cause
damage to the member and erection equipment and can
endanger the safety of erection personnel (Fig. 2). Erectors
have expressed concern that they have no reliable method
to determine the cause of this instability, how to anticipate
it, and how to avoid it.
While the concepts described herein apply to all long
vertical precast concrete members, the discussion and
figures address long nonprestressed wall panels. These
are potentially subject to detrimental visible cracking in
critical architectural finished surfaces that may result from
using handling techniques that address erection safety

only. Thus, tensile stresses at an impact factor of 1.2W are
checked for each lifting-layout configuration against the
recommended maximum of
5 f c' = 354 psi (2.44 MPa)
= weight of panel
RR
= right lifting reaction
RL
= left lifting reaction
where
f c'
= concrete compressive strength at erection

= assume 5000 psi (35 MPa)
RL
RR
c. Crane operator tilts panel by raising top

end allowing lower sling to rotate
through rolling block.
W (c.g.)
RL
RR
b. Crane operator lifts panel in horizontal
position until truck pulls away.
W (c.g.)
a. Panel arrives on truck in horizontal

position.
Figure 1. A panel can be erected with one crane using two operating lines. Note: c.g.= center of gravity; RL = left lifting reaction acting at centerline of rolling block;
RR = right lifting reaction acting at right end of panel; W(c.g.) = panel weight acting at c.g. of panel.
PCI Journal | Wi n t e r 2010
119
R L= W
W (c.g.)
c. Panel suddenly becomes unstable. Top

line goes slack. Panel rotates rapidly to
vertical position, swinging
uncontrollably.
RR
RL
b. Panel feels light to crane operator.

Top line appears to be going slack.
W (c.g.)
RL
RR
a. Crane operator tilts panel by raising top

line. Panel feels stable to crane operator.
W (c.g.)
Figure 2. Panels can experience instability during tilting toward vertical. Note: c.g. = center of gravity; RL = left lifting reaction acting at centerline of rolling block; RR = right
lifting reaction acting at right end of panel; W(c.g.) = panel weight acting at c.g. of panel.
120
Since the mid-1980s, the third edition of the PCI Design

Handbook: Precast and Prestressed Concrete1 and PCIs
Erectors Manual: Standards and Guidelines for the Erec-
tion of Precast Concrete Products2 have addressed this

issue, providing a formula intended to protect against sudden rollover of long wall panels (Fig. 3).
Formula in PCI Erectors Manual and Design Handbook.

Purpose is to protect against erection instability.
e = distance from c.g. to RL centerline with panel in horizontal position.
Panel will be stable during erection if:
L
L2 b 2
e>
a
2
2
a (to c.g.)
RL
sRR
W (c.g.)
eo
b
L
CAUTION: DO NOT USE THE ABOVE FORMULA

IN ITS PRESENT FORM. (Refer to article pages 125128)
Figure 3. The current PCI stability equation shown with Fig. 5.6.2 on page 5-24 of the sixth edition of the PCI Design Handbook: Precast and Prestressed Concrete is incorrect. It is necessary for the c.g. of the precast concrete component to be between the two main crane lines for all angles during the rotation. Note: a = distance from up face
of panel to center of gravity of the panel; b = distance between lower lifting devices; c.g. = center of gravity; eo = distance from the center of gravity of panel to centerline
of rolling-block reaction with panel in horizontal position; L = length of panel; RL = left lifting reaction acting at centerline of rolling block; RR = right lifting reaction acting at
right end of panel; W(c.g.) = panel weight acting at c.g. of panel.
121
However, erectors have indicated that even if the panel lifting points conform to the dimensions derived from the PCI
formula, there have been instances in which unexpected
sudden rollover has occurred.
The author encountered this problem in 1995 during the
erection of a long wall panel produced by Stresscon Corp.
for the Soundtrack project in Denver, Colo. In an analysis
of the incident, the basic concept of safe handling of long
wall panels was recognized and Stresscon adopted a procedure for three-point lifting, imposing restrictions on the
location of the lower sets of lifting devices.
Basic instability concept

As illustrated in Fig. 4, with the panel in its horizontal
position, the rolling-block lifting reaction RL is centered
between the two lower sets of lifting devices. Its vertical alignment is located at a distance eo from the center
of gravity c.g. of the panel toward the lower end of the
panel. As the panel is tilted to its vertical position, RL shifts
toward the c.g. of the panel and its distance e decreases.
As the tilt angle increases further, e may decrease to zero
so that RL aligns with the c.g. of the panel. At that point, RL
carries the entire weight of the panel, the top reaction carries no weight, and the panel becomes unstable, swinging
rapidly to the vertical position as illustrated in Fig. 2 and 4.
RL = W
c. As tilt angle increases further, RL can

align with c.g. of panel, causing panel to
suddenly become unstable.
shift
RL
Tilt Angle
= 45
RR
b. As panel is tilted, e decreases as RL shifts

toward c.g. of panel, creating potential
instability of panel.
W (c.g.)
e
b/2 b/2
b
RL
Tilt Angle
= 0
RR
W (c.g.)
CGL
CGR
a. At zero degrees, RL centered between

lifting devices.
eo
b/2
b/2
b
Figure 4. These diagrams show the fundamental issues as the tilt angle increases. Note: b = distance between lower lifting devices; c.g. = center of gravity; CGL = distance
from left end of panel to c.g. of panel; CGR = distance from right end of panel to c.g. of panel; eo = distance from the center of gravity of panel to centerline of rolling-block
reaction with panel in horizontal position; e = horizontal projection of distance from centerline of center of gravity to centerline of rolling-block reaction with panel in tilted
position; L = length of panel; RL = left lifting reaction acting at centerline of rolling block; RR = right lifting reaction acting at right end of panel; W = weight of panel; W(c.g.)
= panel weight acting at c.g. of panel; = angle between sling leg and surface of panel; = tilt angle of panel in tilted position ( as a subscript identifies horizontal
projection of dimensions with panel in tilted position).
122
RR
R L = 39.44K
e =1'-7"
0'-6"
e=9'-01/2"
8'-6 /2"
W (c.g.)
Tilt Angle
= 75
22'-81/2"
17'-1"
44'-5"
R (kips)
16.06
7.81
5.77
-12.31
-13.91
64.51
M (kip-ft)
RL
RR
0'-6 "
4'-7 /2"
8'-61/2"
22'-81/2"
17'-1"
22'-21/2"
22'-21/2"
44'-5"
Figure 5. A conservative layout prevents instability at all tilt angles. Note: c.g. =
center of gravity; eo = distance from the center of gravity of panel to centerline of
rolling-block reaction with panel in horizontal position; e = horizontal projection of
distance from centerline of center of gravity to centerline of rolling-block reaction
with panel in tilted position; RL = left lifting reaction acting at centerline of rolling
block; RR = right lifting reaction acting at right end of panel; W(c.g.) = panel weight
acting at c.g. of panel; = angle between sling leg and surface of panel; = tilt
angle of panel in tilted position ( as a subscript identifies horizontal projection of
dimensions with panel in tilted position). 1 = 1 in. = 25.4 mm; 1 = 1 ft = 0.305 m.
Conservative
layout procedure
The safeguard against instability is to locate the lower sets
of lifting devices so that throughout the tilting of the long
panels, the rolling-block reaction RL is prevented from
aligning with the c.g. of the panel.
As indicated in Fig. 5, both of the lower sets of lifting
devices are located below the c.g. of the panel. Thus at all
tilt angles, RL is prevented from aligning with the c.g. of
the panel.
5.93'
9.85'
12.85'
Max. Tensile Stress
fc' = 5000psi at erection
ft =
ft
W (c.g.)
11.16'
Allowable Tensile Stress
allow
eo=9'-01/2"
103.23
42.56
-13.33
4.62'
Tilt Angle
= 0
RR =16.06
19.72
19.72
V (kips)
8'-61/2"
W ' (c.g.) = 55.5K
8'-6 /2"
4'-71/2"
RR = 16.06K
12"
RL
= 5 fc' = 354psi
6 103.23 12,000
2
6.94 12 (12)
= 620psi
ft = 620psi Tension (Bottom)

> 354psi allowable
High tensile stresses in bottom face of panel

will cause cracking. 4-point lifting or
prestressing required.
Figure 6. This conservative layout shows shear, moment, and tensile stresses.
Note: c.g. = center of gravity; e = minimum distance from the center of gravity
of the panel, with the panel in its horizontal position, to protect the erection-crew
members against the unexpected sudden rollover of the panel; fc' = concrete compressive strength at erection; ft = actual tensile stress in panel during lifting; ftallow
= allowable tensile stress in panel during lifting; k = K = kip; LF = linear foot; M =
moment; R = reaction; RL = left lifting reaction acting at centerline of rolling block;
RR = right lifting reaction acting at right end of panel; V = shear; W = weight of
panel; W = weight of panel modified by impact factor (1.2W in examples); W(c.g.)
= panel weight acting at c.g. of panel. 1 = 1 in. = 25.4 mm; 1 = 1 ft = 0.305 m;
1 psi = 6.895 kPa; 1 kip = 4.448 kN.
There are other considerations that must be addressed,

even with this conservative procedure. As the panel is
tilted, the load carried by RL increases and the loads applied to the lifting devices increase accordingly, changing
from primarily tension to primarily shear. These loads are
applied to the lower lifting devices at steep angles, potentially exceeding their allowable shear capacity.
As shown in Fig. 6, the conservative layout of the lower
lifting inserts causes the moment in the upper portion of
the panel to dominate. The consequent tensile stresses
in the bottom face of the panel (usually the architectural
finished face) may result in visible cracking of this critical
surface. Concentric prestressing is often required for long
panels erected using the three-point procedure.
123
44'-5"
4'-7 /2" 12'-11 /2"
1
44'-5"
12'-11 /2" 4'-1 /2"
9'-3"
13.87
13.87
13.87
22'-21/2"
13.87
R (kips)
22'-81/2"
0'-6"
22'-21/2"
19.72
19.72
W ' = 55.5K
17'-1"
22'-21/2"
22'-21/2"
R (kips)
4'-7 /2"
W ' = 55.5K
16.06
103.23
2'
64.51 42.56
12.94
M(kip-ft)
12.94
-13.33
-13.33
-13.33
M(kip-ft)
-13.33
-13.33
Panel is stable at all Tilt Angles
Panel 6.94' 44.42' 1.0'

W ' = 46.25 1.2 = 55.5K
Max. Tensile Stress = 80psi
Max. Tensile Stress = 620psi > 354psi

3-Point Lift - Shift Point 2 to Point 2'
Conservative Layout
4-Point Lift - Stripping & Loading

Figure 7. This figure shows the lifting-device layout for the illustrated panel in this
article and the consequent balanced positive and negative moments during loading
on trucks for delivery to jobsites. Note: K = kip; M = moment; R = reaction; W =
weight of panel modified by impact factor (1.2W in examples). 1 = 1 in. = 25.4 mm;
1 = 1 ft = 0.305 m; 1 psi = 6.895 kPa; 1 kip = 4.448 kN; 1 kip-ft = 1.356 kN-m.
Figure 8. This figure shows the moments and maximum tensile stress using the
conservative three-point lifting-insert layout shown in Fig. 6. Note: K = kip; M =
moment; R = reaction; W = weight of panel modified by impact factor (1.2W in
examples). 1 = 1 in. = 25.4 mm; 1 = 1 ft = 0.305 m; 1 psi = 6.895 kPa; 1 kip =
4.448 kN; 1 kip-ft = 1.356 kN-m.
44'-5"
4'-7 /2"
22'-2 /2"
1
R (kips)
44'-5"
22'-21/2"
17'-7"
4'-71/2"
20'-2 /2"
1
22'-2 /2"
1
21.48
21.48
6'-71/2"
12.54
R (kips)
W ' = 55.5K
22'-21/2"
17'-7"
4'-71/2"
22'-21/2"
22.25
22.25
1'
12.54
W ' = 55.5K
85.38
27.34
63.96
M(kip-ft)
50.84
48.25
M(kip-ft)
0.0
-13.33
o
At Tilt Angle = 60
Panel unstable w/sling line = 30ft.
Panel barely stable w/sling line = 40ft.
Max. Tensile Stress = 513psi > 354psi
3-Point lift at points 1 , 3 & top
Figure 9. This figure shows the moments and maximum tensile stress resulting
from three-point lifting using a single line from the top of the panel and the slings
and rolling blocks attached to points 1 and 3 of the four-point lifting configuration.
Note: K = kip; M = moment; R = reaction; W = weight of panel modified by impact
factor (1.2W in examples). 1 = 1 in. = 25.4 mm; 1 = 1 ft = 0.305 m; 1 psi =
6.895 kPa; 1 kip = 4.448 kN; 1 kip-ft = 1.356 kN-m.
124
-27.38
o
At Tilt Angle = 60
Panel unstable w/sling line = 30ft.
Panel stable w/sling line = 40ft.
Max. Tensile Stress = 305psi < 354psi
3-Point Lift - Shift Point 1 to Point 1'
Figure 10. This figure shows the moments and maximum tensile stress resulting
from attaching the rolling-block lines to point 3 and a modified location of point 1,
farther from the bottom of the panel. Note: K = kip; M = moment; R = reaction; W =
weight of panel modified by impact factor (1.2W in examples). 1 = 1 in. = 25.4 mm;
1 = 1 ft = 0.305 m; 1 psi = 6.895 kPa; 1 kip = 4.448 kN; 1 kip-ft = 1.356 kN-m.
Analytical methods
to reduce tensile stresses
Figures 7 through 10 study the effects on panel moments
and stresses resulting from varying the lifting-device
locations. The layout of lifting devices for long panels is
dictated by the condition at stripping of the panels when
the concrete strength is low. The PCI Design Handbook5
shows the recommended layout of lifting devices using
four-point handling of long panels in the horizontal position for stripping and loading on trucks. (This is referred to
as eight-point lifting in the PCI Design Handbook because
there are two devices at each lift point location along the
length of the panel.) For the panel in this article, Fig. 7
shows this lifting-device layout and the consequent balanced positive and negative moments during loading onto
trucks for delivery to jobsites.
Figure 8 repeats the moments and maximum tensile stress
using the conservative three-point lifting-insert layout
shown on Fig. 6 for comparison with the modified layouts
shown in Fig. 9 and 10. Figure 9 shows the moments and
maximum tensile stress resulting from three-point lifting
using a single line from the top of the panel and the slings
and rolling blocks attached to points 1 and 3 of the fourpoint lifting configuration. This results in a reduction
in tensile stress from 620 psi (4.3 MPa) to 513 psi (3.5
MPa), but the analytical stability calculation presented
in this article indicates that the panel becomes unstable
at a tilt angle of about 50 deg with a sling length of 30
ft (9 m). Even with a sling length of 40 ft (12 m), there
is insufficient margin of safety against instability at the
critical tilt angle.
In this article, sling length S is defined as the length of
the cable attached to a lifting device running diagonally
through the rolling block and diagonally back to the companion lifting device that shares the rolling-block reaction.
It includes the lengths of hooks and any shackles within
that length of line.
Figure 10 shows the moments and maximum tensile
stress resulting from attaching the rolling-block lines to
point 3 and a modified location of point 1, farther from
the bottom of the panel. The tensile stress reduces further
to 305 psi (2.10 MPa), but the analytical stability calculation shows that the panel is only marginally stable at the
most critical tilt angle, using a sling length of 40 ft (12
m). Increasing the sling length to 50 ft (15 m) in both of
the previously described cases would ensure stability at
all tilt angles.
The section Analytical StudyShifting of Rolling-Block
Reaction and the sidebar Erecting Long Precast Concrete
Members show two analytical methods that establish
the safe location of lifting devices. However, it must be
understood that the length of the sling running through
the rolling block is a critical variable in these analytical

methods, and that using a shorter sling than indicated may
cause sudden instability of the panel, even though the
lifting-device locations are unchanged.
This raises an important caveat that must be considered
by designers who use this less-conservative layout. It is
essential that the designer be in a position to ensure that
the erection crew is properly notified and understands the
critical importance of using the minimum specified sling
length. If not, this less-conservative layout method may
potentially put members of the erection crew at serious
risk and should not be used.
The conservative layout procedure for three-point lifting
(Fig. 5) is not subject to this risk and is recommended for
use in any situation in which close supervision of the erection crew is not available.
Four-point lifting with two sets

of rolling blocks
Another method to reduce tensile stresses in the critical
face of the panel is to use a four-point layout of lifting
devices and two sets of rolling blocks. As illustrated in
Fig. 11, both the lower and upper reactions are carried by
rolling blocks with upper-block slings engaging the two
upper lifting devices and the lower-block slings engaging
the two lower devices in the conservative locations shown
in Fig. 8.
Figure 11 also shows the moments and maximum tensile stress for the same panel for comparison with those
indicated from Fig. 7 through 10. Although this method
significantly reduces tensile stresses in both faces of the
panel, it is also more expensive and requires additional
erection equipment and extra erection labor to install and
then disengage for each panel lifted.
However, as indicated in Fig. 11, the panel remains stable
through all tilt angles from its horizontal position to its
vertical position. The demonstration photograph sequence
in Fig. 12 further illustrates the stability and clearly shows
the shifting of the rolling-block reactions as the panel is
rotated through all tilt angles.
Check validity of the PCI

Design Handbook formula
As discussed in the Background section, four editions of
the PCI Design Handbook1,3,4,5 and the Erectors Manual2
present a formula that is intended to protect against sudden
rollover of panels being tilted to their vertical position.
Erectors have reported to the author that some long panels
that have lifting-device locations conforming to this formula suddenly became unstable during erection.
125
12.9K
42.6K
Panel is stable at
all Tilt Angles
W ' = 55.5K
= 60
R R = 22.34K
R L = 33.16K
0'-6"
R (kips)
16.58
11.17
16.58
11.17
W ' = 55.5K
22'-21/2"
4'-7 /2"
1
17'-1"
22'-21/2"
5'-1 /2"
1
17'-7"
50.09
33.40
M (kips-ft)
-13.33
-11.12
Max. Tensile Stress = 301psi < 354psi
Figure 11. This figure shows the four-point lifting layout with rolling blocks at both
ends of the panel. Note: K = kip; M = moment; R = reaction; RL = left lifting reaction acting at centerline of rolling block; RR = right lifting reaction acting at right
end of panel; = tilt angle of panel in tilted position ( as a subscript identifies
horizontal projection of dimensions with panel in tilted position). 1 = 1 in. = 25.4
mm; 1 = 1 ft = 0.305 m; 1 psi = 6.895 kPa; 1 kip = 4.448 kN; 1 kip-ft = 1.356
kN-m.
126
Figure 12. This demonstration shows the tilting of a panel with a four-point layout
and rolling blocks at both ends of the panel.
CHECK VALIDITY OF FORMULA IN PCI HANDBOOK AND ERECTORS MANUAL.

DOES IT PROTECT AGAINST INSTABILITY?
Panel Instability Incident: Soundtrack project, June 1995 (Stresscon)
RL = 42.2K
Sling Length = 40'-0"
0'-6" to (c.g.)
PCI Formula
L
L2 - b 2
e > _ - _______ - a
2
2
2
RR = 9.8K
e = 2.55'
e = 6.0' > 2.55'
W (c.g.) = 52K
27'-6"
26'-10"
1'-0"
54.33
(54.33) - (25)
e > _____ - _____________ - 0.5
2
2
e = 6'-0"
OK per formula
8'-4"
12'-6"
12'-6"
21'-0"
b = 25'-0"
L = 54'-4"
Figure 13. This figure shows the soundtrack panel dimensions used in the PCI Design Handbook formula. Note: a = distance from up face of panel to center of gravity of
the panel; b = distance between lower lifting devices; c.g. = center of gravity; K = kip; L = length of panel; RL = left lifting reaction acting at centerline of rolling block;
RR = right lifting reaction acting at right end of panel; W(c.g.) = panel weight acting at c.g. of panel. 1 = 1 in. = 25.4 mm; 1 = 1 ft = 0.305 m.
CHECK VALIDITY OF FORMULA IN PCI HANDBOOK AND ERECTORS MANUAL.

DOES IT PROTECT AGAINST INSTABILITY?
Panel Instability Incident: Soundtrack project, June 1995 (Stresscon)
PCI Formula
If e > 2.55 , stability OK
Actual e = 6.0 > 2.55
R L = 52.51K > W = 52K

RR = -0.51K
Analytical Model
At = 60
RL shifts to right of c.g.
RL carries entire weight of panel > 52k
RR would require downward pull = 510#
to keep panel from rolling
Panel actually rolled in June 1995
As predicted by Analytical Model
W (c.g.) = 52K
e = -11/2"
= 60
PCI FORMULA DID NOT

PREDICT INSTABILITY
Figure 14. This figure compares the formula e with the actual e in unstable soundtrack panel. Note: c.g. = center of gravity; e = minimum distance from the center of
gravity of the panel, with the panel in its horizontal position, to protect the erection-crew members against the unexpected sudden rollover of the panel; e = horizontal projection of distance from centerline of center of gravity to centerline of rolling-block reaction with panel in tilted position; RL = left lifting reaction acting at centerline of rolling
block; RR = right lifting reaction acting at right end of panel; W = weight of panel; W(c.g.) = panel weight acting at c.g. of panel; = tilt angle of panel in tilted position
( as a subscript identifies horizontal projection of dimensions with panel in tilted position); # = pound. 1 = 1 in. = 25.4 mm; 1 = 1 ft = 0.305 m.
127
To evaluate the validity of this formula, the panel used for

the following example is the Soundtrack wall panel, which
became unstable during tilting. Figure 13 shows the formula
along with the corresponding dimensions of the lifting-device locations, panel thickness, and location of the c.g. of the
panel. The length of the rolling-block sling was 40 ft (12 m).
The PCI Design Handbook1 formula calculates the minimum e required to protect the erection-crew members
against the unexpected sudden rollover of the panel when it
is in the horizontal position. In this case, the actual e = 6.0
ft (1.8 m), which comfortably exceeds the minimum e =
2.55 ft (0.78 m) derived from the formula.
However, as indicated in Fig. 14, the analytical method
shows that, with the sling length of 40 ft (12 m), the panel
becomes unstable at a tilt angle of 60 deg. In fact, the
Soundtrack panel became unstable during erection. The
bottom end hit the ground abruptly, and the panel was
severely damaged. Fortunately, all erection-crew members
escaped without injury. With a sling length of 50 ft (15 m),
the analytical methods show that the panel would probably
have been stable throughout the tilting process.
Erectors have also reported to the author other documented
rollover incidents wherein the dimensional information and
sling lengths were available. In each case, the PCI Design
Handbook formula indicated that the formula-derived
lifting-device locations should have protected the panel
from sudden rollover, whereas the analytical methods,
which include sling-length effects, predicted the instability
that was actually encountered.
In its present form, the PCI Design Handbook formula
does not include the critical sling-length variable and
therefore does not provide its intended protection against
instability. Instead of addressing possible modifications to
the PCI Design Handbook formula, this article provides
the analytical methods described in the section Analytical StudyShifting of Rolling-Block Reaction and the
sidebar Erecting Long Precast Concrete Members, which
directly model the shifting location of the RL reaction and
enable the designer to vary the length of the sling for any
case studied.
At the time this article was written, PCI had transmitted a
technical bulletin to the industry on December 19, 2008,
then published the bulletin in the Spring 2009 edition of
the PCI Journal,6 indicating that the formula in its present
form is incorrect and may not provide stability for all conditions when rotating a precast concrete component in the
air. PCI has further initiated action to remove the formula
from future editions of both the PCI Design Handbook1
and the Erectors Manual2 and to recommend that the
conservative layout shown in Fig. 5 be used for three-point
lifting of long vertical precast concrete members.
128
However, design engineers are hereby cautioned that the

PCI Design Handbook1 formula, in its present form, is
represented in current and past editions of these publications as providing protection against sudden rollover, and
precautionary procedures should be instituted to ensure
against its use without a verified modification that incorporates the sling-length variable.
Conclusion
Beneficial effect of longer sling
lengths
Through studies of various hypothetical conditions and
analyses of incidents that resulted in the sudden rollover
of members while using the three-point pickup, it became
apparent that increasing the length of the slings would
often protect against this condition. Based on these studies,
it appears that a simple rule may be applicable in cases in
which the erector is confronted with having to evaluate the
potential for sudden rollover of long vertical precast concrete members already cast with lifting devices in place.
Erectors quick rule
For the three-point lifting procedure, it is suggested that
the minimum sling length be greater than twice the distance between the two lower lifting devices to which it is
attached. For example, if that distance is 25 ft (7.5 m), a
minimum sling length of 50 ft (15 m) plus 10 ft (3 m), or
a total minimum sling length of 60 ft (18 m), is suggested.
However, to verify the safety of this quick rule, for any
specific case it is critical that the resulting sling length be
checked and verified by analytical methods, such as those
presented in the section Analytical StudyShifting of
Rolling-Block Reaction and the sidebar Erecting Long
Precast Concrete Members.
Recommendations to designers
The analytical methods shown in the section Analytical StudyShifting of Rolling-Block Reaction and the
sidebar Erecting Long Precast Concrete Members are
also recommended to be used to establish lifting-device
locations in situations in which the designer elects not to
conform to the recommended conservative lifting-device
layout in Fig. 5.
However, the following must be emphasized:

The designer must be in a position to guarantee that

the sling length required by the calculation is actually
used by the erection crew.
The location of the c.g. of the member must be clearly

defined. A wall panel with openings near the top
of the panel or with the top portion thinner than the
bottom shifts the c.g. toward the bottom, which may

result in the panel becoming unstable if the calculation
is based on the c.g. being at midheight of the panel.

While the analytical methods are capable of calculating the eccentricity between the vertical alignments
of the c.g. of a member and the rolling-block reaction
through all tilt angles, engineering judgment should
be exercised in establishing a required minimum value
for this eccentricity to ensure that it is increased by an
adequate factor of safety to account for manufacturing
tolerances and other imperfections.
The analytical methods should also be used to calculate

the loads in the slings and the angles to which they apply
loads to the lifting devices, particularly in cases in which
the rated capacity of a lifting device is less in shear than in
tension.
Analytical studyshifting
of rolling-block reaction
This method compares the vertical alignment of the
rolling-block reaction with the vertical alignment of the
c.g. of long precast concrete members at any selected tilt
angle. If at any tilt angle the rolling-block reaction aligns
with the c.g., that reaction will carry the entire weight of
the member and the member will become unstable.
Figure 15 illustrates this method. The input data utilize
values given for each of the notations illustrated on Fig. 16
with the panel in the horizontal position. Those input data
are shown in the highlighted boxes in the example.
The notations at any tilt angle are shown on Fig. 17. During the tilting of a member, the horizontal components of
the loads T in the two legs of the rolling-block sling
(T sin ) must be equal and opposite. Thus the angle of inclination of each leg with respect to the vertical alignment of
the rolling-block reaction must also be equal and opposite.
At any tilt angle , the method requires the selection
of trial values of , calculates the consequent values of
dimensions q and p until, through successive approximations, tan = q/p. At that value of , the method calculates the horizontal shift of the vertical alignment of RL
and its eccentricity e with respect to the vertical alignment
of the c.g. of the member.
If, at any selected tilt angle, e approaches zero value or
becomes negative, the panel becomes unstable and will roll
suddenly and uncontrollably.
If the value of e remains positive through all tilt angles,
the member will remain stable. However, it is emphasized
that the selected sling length S is a very important variable
and its length must be established and controlled so that
this or any other analytical method may be relied on to

ensure the safe erection of these long members.
In the example, this method is applied to the long wall
panel that rolled suddenly during erection on the 1995
Soundtrack project. The required input data are taken from
the panel dimensions with the panel in its horizontal position and are highlighted in yellow. The sling length used to
erect the Soundtrack panel was about 40 ft (12 m).
Figure 17 illustrates the panel at tilt angle . The value of
is checked at 60 deg in the example, and the value of
is varied until tan = q/p. The resulting value of
=18.2deg, and at that value the vertical alignment of the
rolling-block reaction RL has shifted beyond the vertical
alignment of the c.g. of the panel. The value of e becomes
negative by 1.54 in. (39 mm), and the panel becomes
unstable.
The calculations in the example show that at RR, a downward pull of 0.51 kip (2.3 kN) would be required to keep
the panel stable, and RL carries the entire weight of the
panel. The tension in one of the two sling lines would be
13.56 kip (60 kN) applied at the lower lifting device at
angle = 11.8 deg with respect to the panel surface.
This method also checks the validity of the PCI Design
Handbook1 formula and calculates the minimum value of e
= 2.55 ft (0.78 m) with the panel in the horizontal position,
at which point the panel should be stable. However, the
actual value of e is 6.0 ft (1.8 m), but the panel has become
unstable at a tilt angle = 60 deg, with a sling length S =
40 ft (12 m). Thus the PCI Design Handbook formula did
not predict the instability of the panel.
If the sling length S is changed to 50 ft (15 m), the method
will show that the panel remains stable at all tilt angles.
However, engineering judgment should be exercised
with respect to establishing a safety factor to increase the
minimum required eccentricity at the critical tilt angle to
account for manufacturing tolerances and other variables
associated with the erection process.
Acknowledgments
The author appreciates valuable input, detailed review,
suggestions, and editing by Helmuth Wilden, P.E., of
Wilden Enterprises and Steve Seguirant, P.E., of Concrete
Technology Corp. Also providing comments were John
Jacobsen, P.E., Peter Robinson, Mike Larsen, and Dennis
Cates of Stresscon Corp. and Mike Dixon, P.E., of FDG
Associates. The demonstration of the four-point lifting
sequence was performed by Stresscon Corp., and its photographic sequence was provided by Ralph Brandhorst.
Diagrams were put into digital form by Austin Bryan of
CAD Prototypes LLC.
129
LIFTING ANGLE EFFECT ON PANEL REACTIONS

Notations Illustrated on Figs. 16 and 17
DON LOGAN
SOUNDTRACK 1995-STYROCORE PANEL 10 FT 54.33 FT;

3 POINT PICKUP, b(Lower) =
25.00 ft
54.33
40.00
25.00
8.33
27.50
26.83
6.50
6.00
L=
SL =
b=
c=
CG(R) =
CG(L) =
f=
e=
SELECT =
ft
ft
ft
ft
ft
ft
ft
ft
09/30/09
THICKNESS =
12.00 in.
a=
0.500 in.
BOTTOM RIGGING
PANEL LENGTH
SLING LENGTH
CHECK VALIDITY OF PCI FORMULA
pci e = L/2 {[(L2 b2)0.5]/2} a
pci e = 2.547 ft
If e(actual) > pci e, then stable
e(actual) = 6.000 ft > pci e, OK?
60.00 deg
0.866
0.500
sin =
cos =
a*sin =
b =
b*cos =
12.500 ft
p =
b*sin =
21.651 ft
f =
f *cos =
3.250 ft
f' = f - (a*sin) =
2.817 ft
CG(R) = [CG(R)*cos] a*sin)

TRY =
0.433 ft
13.317 ft
18.211 deg
j =
p/cos =
22.792 ft
k =
(SL j)/2 =
8.604 ft
m =
k*sin =
2.689 ft
q =
b 2m =
7.122 ft
n =
k*cos =
8.173 ft
e =
m f' =
-0.128 ft;
q/p = tan =
CHECK
SHIFT
= b/2 m
W =
* 12 = -1.538 in.
tan =
0.329
3.561 ft ; *12 =
42.73
0.329
52 K ; ALPHA = 90
UNSTABLE
11.79 deg
RR = W*e/(CG(L) + e)
-0.51 K downward*
RL = [W*(CG(L)/[CG(L) + e]
5251 K vertical*
Line Tens. (4 components) = RL/(4*cos) =
13.82 K resultant
* NOTE:
v3
THE RL REACTION LINE HAS SHIFTED PAST THE CG LINE AND RL CARRIES ENTIRE PANEL
WEIGHT; RR < ZERO KIPS. PANEL IS UNSTABLE.
Figure 15. This Microsoft Excel diagram shows the lifting angles effect on panel reactions. Note: b = distance between lower lifting devices; L = length of panel; SL = S
= sling length, defined as length of cable attached to lifting device, running diagonally through rolling block and diagonally back to companion lifting device that shares
rolling-block reaction, includes lengths of hooks and any shackles within that length of line; W = weight of panel; = tilt angle of panel in tilted position ( as a subscript
identifies horizontal projection of dimensions with panel in tilted position); = angle of inclination. 1 in. = 25.4 mm; 1 ft = 0.305 m.
130
eo
fo
RL
Tilt Angle
=0
o o
SL/2
SL/2
RR
a
CG(L)
b/2
c
CG(R)
b/2
L-(c+b)
b
L
Panel in horizontal position showing notations

Refer to Fig. 15 for specific dimensions
of unstable Soundtrack panel 1995
Figure 16. Notations are given for the panel when it is in the horizontal position. Note: a = distance from up face of panel to center of gravity of the panel; b = distance
between lower lifting devices; eo = distance from the center of gravity of panel to centerline of rolling-block reaction with panel in horizontal position; L = length of panel; RL
= left lifting reaction acting at centerline of rolling block; RR = right lifting reaction acting at right end of panel; SL = S = sling length, defined as length of cable attached to
lifting device, running diagonally through rolling block and diagonally back to companion lifting device that shares rolling-block reaction, including lengths of hooks and any
shackles within that length of line; W = weight of panel; = angle between sling leg and surface of panel; = tilt angle of panel in tilted position ( as a subscript identifies horizontal projection of dimensions with panel in tilted position).
131
b /2
RL
RL Shift
f'
-e unstable
b/2
b/2
2m
CG(R)
RL Shift
f'
-e unstable
=
tan = q / p
RR
(-)
RL
k
m m
T
j
fo
fo
Tilt Angle =
b/2
b/2
b
a sin
f-asin
f
Shift in CG
(panel thickness effect)
Panel ininstability at tilt angle illustrated

Refer to Fig. 15 for specific dimensions
of unstable Soundtrack panel 1995
Figure 17. Panel instability is shown for tilt angle . Note: a = distance from up face of panel to center of gravity of the panel; b = distance between lower lifting devices;
e = horizontal projection of distance from centerline of center of gravity to centerline of rolling-block reaction with panel in tilted position; RL = left lifting reaction acting at
centerline of rolling block; W = weight of panel. = tilt angle of panel in tilted position ( as a subscript identifies horizontal projection of dimensions with panel in tilted
position).
132
References
RL
= left lifting reaction acting at centerline of rolling

block
1. Industry Handbook Committee. 1985. PCI Design

Handbook: Precast and Prestressed Concrete. MNL120. 3rd ed. Chicago, IL: PCI.
RR
= right lifting reaction acting at right end of panel
= sling length, defined as length of cable attached

to lifting device, running diagonally through
rolling block and diagonally back to companion
lifting device that shares rolling-block reaction,
including lengths of hooks and any shackles
within that length of line
= tension in the rolling block sling
= weight of panel
= weight of panel modified by impact factor (1.2W

in examples)
2. PCI Erectors Committee. 1999. Erectors Manual:

Standards and Guidelines for the Erection of Precast
Concrete Products. MNL-127. 2nd ed. Chicago IL:
PCI.
Handbook: Precast and Prestressed Concrete. MNL120. 4th ed. Chicago, IL: PCI.
W(c.g.) = panel weight acting at c.g. of panel

= angle between sling leg and surface of panel
6. PCI Journal. 2009. Figure on Stability during Handling and Erection to Be Revised. In From PCI Headquarters. V. 54, No. 2 (Spring): p. 21.
= tilt angle of panel in tilted position ( as a

subscript identifies angles and dimensions with
panel in tilted position)
Notation
= angle of inclination between sling legs and centerline of rolling block reaction
= distance from up face of panel to center of gravity of the panel
= distance between lower lifting devices
c.g.
= center of gravity
CGL
= distance from left end of panel to c.g. of panel
CGR
= distance from right end of panel to c.g. of panel
eo
= distance from the center of gravity of panel to

centerline of rolling-block reaction with panel in
horizontal position
= horizontal projection of distance from centerline

of center of gravity to centerline of rolling-block
reaction with panel in tilted position
f c'
= concrete compressive strength at erection
ft
= actual tensile stress in panel during lifting
ftallow
= allowable tensile stress in panel during lifting
= length of panel
133
Erecting long precast

concrete members
S = sling length, defined as total length of lifting sling

from lowest set of lifting devices through the rolling
blocks to middle set of lifting devices
This sidebar shows the method that Concrete Technology

Corp. uses to evaluate the stability of long precast concrete members lifted using three points during erection.
This method is based on the law of cosines and is simple
to understand and incorporate into a spreadsheet.
In the horizontal position, the panel hangs as shown in
Fig. S1. The only information required as input for the
method is:
dcg
= distance from up face of panel to c.g. of panel
hcg
= distance from bottom of panel to c.g. of panel

= distance from bottom of panel to lowest set of
lifting devices
Rl
= distance between lower two sets of lifting devices
L = length of panel
Stephen J. Seguirant, P.E.

Vice president and director of engineering
Concrete Technology Corp., Tacoma, Wash.
h1
h2
In the horizontal position, the length of the lower leg

of the sling S1 and the upper leg of the sling S2 are both
equal to S/2. During all angles of rotation, S1 + S2 = S.
When the panel reaches vertical, S1 = S - (S - h2)/2 and S2
= S - S1. By varying S1 between the possible extremes, the
stability of the panel during rotation can be investigated.
Figure S2 shows the panel in a tilted position. Because
the distance between the lower two sets of lifting devices
h2 is fixed, angles A and B can be found by the law of
cosines for any assumed value of S1.
A = cos1
S12 + S22 h22

2S1S2
B = cos1
h22 + S22 S12

2h2 S2
Rr
S 1 = S/2
Rl
Rr
S 2 = S/2
60 o min
S2
d cg
Equal
B
eh
S1
C
h cg
h1
h2
h3
L
x lift
Panel in horizontal position.
Figure S1. The panel hangs like this when it is in the horizontal position. Note: c.g.
= center of gravity; dcg = distance from up face of panel to c.g. of panel; eh = distance from c.g. of panel to Rl; hcg = distance from bottom of panel to c.g. of panel;
h1 = distance from bottom of panel to lowest set of lifting devices; h2 = distance
between lower two sets of lifting devices; h3 = length of panel minus (h1 plus h2); L
= length of panel; Rl = left lifting reaction acting at centerline of rolling block; Rr =
right lifting reaction acting at right end of panel; S = sling length, defined as total
length of lifting sling from lowest set of lifting devices, through the rolling blocks, to
middle set of lifting devices; S1 = the length of the lower leg of the sling; S2 = the
length of the upper leg of the sling.
134
x cg
Panel in tilted position.
Figure S2. The panel is in a tilted position. Note: A = angle; B = angle; C = angle;
e = eccentricity; Rl = left lifting reaction acting at centerline of rolling block; Rr =
right lifting reaction acting at right end of panel; S1 = the length of the lower leg
of the sling; S2 = the length of the upper leg of the sling; xcg = distance between
the bottom up-face corner of the panel and the c.g. of the panel; xlift = distance
between the bottom up-face corner of the panel and the vertical crane line reaction
Rl; = angle of panel rotation from horizontal.
Table S1. Stability calculation results for example panel from Analytical Study Shifting of Rolling-Block Reaction
S1, ft
S2, ft
A, deg
B, deg
, deg
xcg, ft
xLift, ft
e, ft
20.00
20.00
77.36
51.32
0.00
26.83
20.83
6.00
n.a.
21.56
18.44
76.92
57.15
5.62
26.75
21.71
5.05
1.563
23.13
16.88
75.57
63.61
11.40
26.40
22.34
4.07
1.563
24.69
15.31
73.17
70.94
17.52
25.74
22.66
3.08
1.563
26.25
13.75
69.47
79.52
24.26
24.67
22.55
2.11
1.563
27.03
12.97
67.01
84.47
27.97
23.93
22.28
1.65
0.781
27.81
12.19
64.01
90.00
32.01
23.02
21.81
1.21
0.781
28.59
11.41
60.35
96.29
36.47
21.88
21.07
0.80
0.781
29.38
10.63
55.81
103.61
41.51
20.42
19.99
0.44
0.781
29.77
10.23
53.11
107.78
44.33
19.54
19.27
0.28
0.391
30.16
9.84
50.04
112.39
47.41
18.53
18.39
0.13
0.391
30.55
9.45
46.51
117.57
50.82
17.34
17.32
0.01
0.391
30.94
9.06
42.37
123.49
54.67
15.92
16.00
-0.08
0.391
31.40
8.60
36.42
131.79
60.00
13.85
13.98
-0.13
0.459
31.79
8.21
29.85
140.74
65.66
11.51
11.62
-0.11
0.391
32.18
7.82
20.48
153.23
73.47
8.11
8.09
0.02
0.391
32.50
7.50
0.00
180.00
90.00
0.50
0.00
0.50
0.322
, ft
Note: A = angle; B = angle; e = eccentricity; S1 = the length of the lower leg of the sling; S2 = the length of the upper leg of the sling; xcg = distance
between the bottom up-face corner of the panel and the c.g. of the panel; xlift = distance between the bottom up-face corner of the panel and the vertical crane line reaction Rl; = dimensional increment used to modify S1 during the rotation of the panel to vertical; = angle of panel rotation from
horizontal.
Due to the free rotation of the rolling blocks, angle A is

bisected by the crane line resisting Rl at all angles of rotation. Consequently, the angle of panel rotation can be
found using
A
= 90 180 B
2
The distance between the bottom up-face corner of the

panel and the vertical crane line reaction Rl can be found
using
xlift = cos h1 + h2 sin
A
S
2 2
( )
The distance between that same bottom up-face corner

and the c.g. of the panel, adjusted for the depth of the c.g.
below the up face, is
xcg = cos(hcg + dcg tan)
e = xcg xlif t 0
The results of this method on the example illustrated in
the section Analytical Study Shifting of Rolling-Block
Reaction are tabulated in Table S1. The values designated are used to modify S1 for the entire range of rotation. The mesh of values decrease as the panel rotation
angle increases because instability is more likely to occur
at higher tilt angles. At S1 = 31.40 ft (9.6 m), has been
manually adjusted to result in a panel tilt angle of 60
deg. The resulting e = -0.13 ft = -1.54 in. (39 mm) agrees
with the results of the method shown in Analytical
StudyShifting of Rolling-Block Reaction. However,
actual instability will begin at roughly = 50 deg.
The mathematical method presented herein is straightforward. However, engineering judgment should be
exercised with respect to a minimum required eccentricity (greater than zero) to account for manufacturing
tolerances and other imperfections associated with the
erection process.
The panel will remain stable as long as
135
About the author

Donald R. Logan, P.E., is
principal of Logan Structural
Research Foundation in Colorado
Springs, Colo. He was founder
and CEO of Stresscon Corp. from
1967 to 2007. He is a PCI Fellow
and was named a Titan of the
Industry in 2004. Logan received the Martin P. Korn
Award and the American Society of Civil Engineers
T. Y. Lin Award for his 1997 paper on strand-bond
acceptance criteria and the Korn Award again for his
2007 paper on eccentrically loaded L-spandrels. He
serves on the PCI Research and Development Committee.
Synopsis
Erection of long, vertical precast concrete members
from their as-delivered horizontal position to their
vertical position in the structure involves devising
handling procedures that protect the safety of the erection personnel while preventing the precast concrete
member from cracking during the tilting procedure.
The author investigates the most commonly used
procedures, three-point and four-point rolling-block
lifting systems, and identifies a common instability
136
condition that causes sudden, uncontrolled rolling

of the members as they are being tilted toward their
vertical position. Methods are devised to detect in any
member the potential for such instability, to establish
safe location of lifting devices and minimum lengths
of crane slings to prevent this condition from occurring, and to analyze and control tensile stresses from
causing cracking of long precast concrete wall panels
as they are lifted from their horizontal position, rigged
for the tilting operation.
Keywords
Erection, long members, rolling block, safety, stability, tilting, wall panel.
Review policy
This paper was reviewed in accordance with the
Precast/Prestressed Concrete Institutes peer-review
process.
Reader comments
Please address any reader comments to PCI Journal
editor-in-chief Emily Lorenz at elorenz@pci.org or
Precast/Prestressed Concrete Institute, c/o PCI Journal,
209 W. Jackson Blvd., Suite 500, Chicago, IL 60606. J

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Erecting long,

Editors quick points

W int e r 2 0 1 0 | PCI Journal

Erectors have reported incidents that occurred while using

using handling techniques that address erection safety

5 f c' = 354 psi (2.44 MPa)

= right lifting reaction

= left lifting reaction

= concrete compressive strength at erection

c. Crane operator tilts panel by raising top

b. Crane operator lifts panel in horizontal

position until truck pulls away.

a. Panel arrives on truck in horizontal

c. Panel suddenly becomes unstable. Top

b. Panel feels light to crane operator.

a. Crane operator tilts panel by raising top

W int e r 2 0 1 0 | PCI Journal

Since the mid-1980s, the third edition of the PCI Design

tion of Precast Concrete Products2 have addressed this

Formula in PCI Erectors Manual and Design Handbook.

CAUTION: DO NOT USE THE ABOVE FORMULA

Basic instability concept

c. As tilt angle increases further, RL can

b. As panel is tilted, e decreases as RL shifts

a. At zero degrees, RL centered between

W int e r 2 0 1 0 | PCI Journal

Max. Tensile Stress

fc' = 5000psi at erection

Allowable Tensile Stress

W ' (c.g.) = 55.5K

ft = 620psi Tension (Bottom)

High tensile stresses in bottom face of panel

There are other considerations that must be addressed,

PCI Journal | Wi n t e r 2010

Panel is stable at all Tilt Angles

Panel 6.94' 44.42' 1.0'

Max. Tensile Stress = 620psi > 354psi

4-Point Lift - Stripping & Loading

W int e r 2 0 1 0 | PCI Journal

the rolling block is a critical variable in these analytical

Four-point lifting with two sets

Check validity of the PCI

PCI Journal | Wi n t e r 2010

Max. Tensile Stress = 301psi < 354psi

W int e r 2 0 1 0 | PCI Journal

CHECK VALIDITY OF FORMULA IN PCI HANDBOOK AND ERECTORS MANUAL.

CHECK VALIDITY OF FORMULA IN PCI HANDBOOK AND ERECTORS MANUAL.

R L = 52.51K > W = 52K

PCI FORMULA DID NOT

To evaluate the validity of this formula, the panel used for

W int e r 2 0 1 0 | PCI Journal

However, design engineers are hereby cautioned that the

The designer must be in a position to guarantee that

The location of the c.g. of the member must be clearly

bottom shifts the c.g. toward the bottom, which may

The analytical methods should also be used to calculate

this or any other analytical method may be relied on to

PCI Journal | Wi n t e r 2010

LIFTING ANGLE EFFECT ON PANEL REACTIONS

SOUNDTRACK 1995-STYROCORE PANEL 10 FT 54.33 FT;

CG(R) = [CG(R)*cos] a*sin)

Line Tens. (4 components) = RL/(4*cos) =

W int e r 2 0 1 0 | PCI Journal

CG(R) = [CG(R)cos] asin)

= left lifting reaction acting at centerline of rolling

= right lifting reaction acting at right end of panel

= sling length, defined as length of cable attached

= weight of panel modified by impact factor (1.2W

= tilt angle of panel in tilted position ( as a

= distance from up face of panel to center of gravity of the panel

= distance from the center of gravity of panel to

= horizontal projection of distance from centerline

S = sling length, defined as total length of lifting sling