Precast Concrete
QA inspection checklist

Delivery & Inspection

1. 1.

   Elements match approved drawings and schedule
   What to look forEach element carries a unique mark cross-referencing the GA and erection drawings. Dimensions, projecting reinforcement, cast-in items (sockets, plates, ducts) all match latest revision. Delivery note matches piece schedule and load list.
   Acceptable whenDimensional tolerance to BS EN 13369 / BS EN 13225 (linear elements): length ±10 mm or L/1000 (whichever greater up to 20 m); cross-section ±5 mm; squareness ±5 mm/m. Cast-in item position ±10 mm.
   StandardBS EN 13369:2018 — Common rules for precast concrete products. BS EN 13225:2013 — Linear precast structural elements. BS EN 1992-1-1 (Eurocode 2).
   Common defectsElement delivered to old drawing revision — connection holes do not alignCast-in plate at wrong position — site re-drilling requiredLength error > 10 mm — bearing detail compromisedMark unreadable or wrong — wrong piece installed in wrong location
2. 2.

   No cracks, chips, or damage
   What to look forVisual inspection of all faces under good light. No structural cracks > 0.3 mm. Edges and arrises clean — no spalls > 25 mm. Soffit free from honeycombing. Lifting socket areas intact. Coloured/exposed-aggregate finishes match approved sample.
   Acceptable whenPer BS EN 13369 Annex F: surface defects classified — minor blowholes < 15 mm dia and < 6 mm depth acceptable in non-visible faces. No cracks > 0.3 mm in service or > 0.2 mm in aggressive exposure. No structural cracks (i.e. across reinforcement).
   StandardBS EN 13369:2018. BS EN 1992-1-1:2004+A1:2014. PCA Handbook of Precast Concrete.
   Common defectsEdge spalls from poor handling — affect bearing or appearanceCracks across element — possible pre-stress release damageHoneycombing on soffit — formwork pour defectReinforcement cover loss visible — durability concernLifting socket damaged in transit — element cannot be lifted
3. 3.

   Lifting points intact and correct
   What to look forCast-in lifting sockets or proprietary anchors (Halfen, Anchor Diamond) at positions per design and matching the lifting clutches available on site. Threads clean, no concrete blockage. Capacity stamped or referenced on element. Spreader beam/sling angle within design limits.
   Acceptable whenLifting anchors per BS EN 13155 with declared capacity ≥ 1.4 × element weight (dynamic factor). Sling angle to lifting axis as per cast-in anchor design (typically max 60° from vertical). All lifting points engaged simultaneously.
   StandardBS EN 13155:2003+A2:2009 — Non-fixed load lifting attachments. BS 7121-1 / LOLER 1998. PCA Lifting and Erection Guide.
   Common defectsWrong clutch type — does not engage anchor threadConcrete in socket — clutch only partially engages, dangerousTwo-point lift used where four-point required — overloadLifting via reinforcement loops not designed for liftingNo identification of capacity — relying on assumption
4. 4.

   CE marking and product certification available
   What to look forDeclaration of Performance (DoP) per element type, traceable to manufacturer's factory production control (FPC) certificate. Concrete strength class, exposure class, fire resistance and reinforcement details declared. Manufacturer ISO 9001 / 14001 / 45001 certificates current.
   Acceptable whenCE/UKCA mark mandatory under Construction Products Regulation. DoP per BS EN 13369 / element-specific harmonised standard (13225, 13224, 13693, etc.). FPC certificate from notified body. Concrete to BS EN 206 strength and exposure class as design.
   StandardConstruction Products Regulation (UK CPR). BS EN 13369:2018. BS EN 206:2013+A2:2021 — Concrete specification.
   Common defectsNo DoP supplied — non-compliant importFPC certificate expired or lapsedStrength class on DoP lower than designWrong exposure class — durability not assured

Installation

1. 5.

   Elements installed to correct position and level

   Record: Deviation (mm)
   What to look forElements set to surveyed gridlines and bench marks. Plumb on columns checked with theodolite or laser plumb at top before release. Top-of-element level checked at both ends. Bearing position central on support — not edge-bearing.
   Acceptable whenPer BS EN 13670 / NSCS: position ±10 mm; verticality ±h/300 or 15 mm (whichever less); top of element level ±10 mm; bearing position ±10 mm of design. Cumulative drift in multi-storey ≤ h/500.
   StandardBS EN 13670:2009 — Execution of concrete structures. BS EN 1992-1-1:2004+A1:2014. PCA Erection Manual.
   Common defectsColumn out of plumb — not corrected before release of craneBearing edge-loaded — high local stress, spallingBeam off design line — connections will not alignCumulative drift in tall columns — top floor significantly off
2. 6.

   Bearing pads / packing correct
   What to look forBearing pads (neoprene, mortar dabs, or steel shims) match design type and thickness. Pad positioned centrally under load path. No edge bearing. Mortar bedding (where used) full and free from voids. Levelling shims removed or grouted in.
   Acceptable whenBearing per BS EN 1992-1-1 / PD 6687: minimum nominal bearing length per design (typically 75-150 mm for floor units). Neoprene pads to BS EN 1337-3, hardness 60 IRHD typical. Mortar bedding M30 minimum, fully filled.
   StandardBS EN 1337-3:2005 — Elastomeric bearings. BS EN 1992-1-1:2004+A1:2014. NSCS / PCA Erection Manual.
   Common defectsBearing pad missing — direct concrete-to-concrete contact, spallingPad off-centre — eccentric bearing reactionVoids in mortar bed — under-bearing leads to crackingWrong pad hardness — too soft, excessive deflectionSteel shims left in (not designed-for) — point load on element
3. 7.

   Connections complete (dowels, ties, welds)
   What to look forAll design connections — dowels in sockets, peripheral tie reinforcement, welded plate connections, post-tensioned ties — complete before subsequent loading. Dowel grout fully filling sockets. Welds of correct size with no cracks. Tie steel laps to design.
   Acceptable whenRobustness ties to BS EN 1992-1-1 / Approved Document A — peripheral, internal, horizontal, and vertical ties at each floor. Dowel grout ≥ design strength (typically C50/60 non-shrink). Welds to BS EN 1090-2 EXC2/3 with VT inspection.
   StandardBS EN 1992-1-1:2004+A1:2014 — Robustness ties. Approved Document A (Structure). BS EN 1090-2:2018 (welded connections).
   Common defectsPeripheral tie not lapped through internal columns — disproportionate collapse riskDowel socket part-grouted — voids visibleWeld undersized or cracked — connection capacity reducedTie reinforcement not continuous through jointWelder unqualified for the procedure
4. 8.

   Grouting of joints complete and finished
   What to look forAll joints between elements (vertical between columns, horizontal at floor seating, longitudinal between hollow-core units) fully grouted. Surface finished off — no voids, slumps, or steps. Grout has bonded to concrete substrate (not cold-pulled).
   Acceptable whenGrout to BS EN 1504-6 or proprietary non-shrink (CGM Sika, Setcrete, Conbex). Strength typically ≥ 50 MPa at 28 days. Joint surfaces pre-wetted prior to grout. Grout cures under damp protection 24 hours minimum.
   StandardBS EN 1504-6:2006 — Anchoring of reinforcing steel bar. BS EN 13670:2009. PCA Hollowcore Floor Systems Code of Practice.
   Common defectsHollowcore joints not grouted — diaphragm action absentGrout shrinkage cracks — no bond to substrateTop of column joint left open — vertical tie not engagedVoids in vertical joints — visible from below as honeycombWrong grout (high shrinkage) used — separation cracks
5. 9.

   Temporary propping in place until permanent stability
   What to look forAdjustable steel props or push-pull stays at column tops, beam mid-spans where required, and slab edges. Props on solid bearings. Cross-bracing of erected frame in two directions. Propping not removed until temporary works engineer / TWC permits.
   Acceptable whenPer temporary works design and BS 5975. Props rated for design load with safety factor (typically 1.5). Permit-to-load and permit-to-strike system in operation. Props remain until concrete topping reaches design strength or permanent connections complete.
   StandardBS 5975:2019 — Temporary works. PCA "Temporary stability of precast concrete structures". CIRIA C732.
   Common defectsProps removed too early — element collapses or shiftsPush-pull stays not in two directions — frame still unstableProp on soft ground — settles under loadNo permit system — props pulled by next trade without authorityProps overloaded — design capacity exceeded

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