01 lfs technical and product manual

PRODUCT GUIDE AND
PRECAST TECHNICAL MANUAL

The professional choice for all your precast
concrete anchors and accessories

Tel: 0044 (0) 1302 745838 Fax: 0044 (0)1302 745839 E-mail: sales@liftingandfixing.co.uk web: www.liftingandfixing.co.uk

1

LFS Product and Technical Manual

Contents

Page 3-4 Precast Concrete Lifting Design

Page 5-22 Capstan Transport Anchor Systems

Page 23—41 Threaded Lifting Systems

Page 46—62 Spread Anchor System

Page 63 Plastic Accessories


2

Precast Concrete Lifting Design

The selection of lifting devices should be carefully made dependant on the type of lift or lifts that the unit will
be subject to once manufactured. It is vitally important to ensure both safe lifting and that no damage to the
concrete occurs. When assessing the lifting of a unit the following factors must be considered.

The Weight of the Unit
The dead weight of a normal precast unit should be calculated using a concrete density of 2500kN/m2. The
theoretical weight can be calculated either mathematically via the dimensions of the unit or through design
packages. The adhesion to the mould must also be included in the calculation of forces dependant on the type
of mould that the unit is cast in. The following can be used as a guide:

Oiled steel mould = 1kN/m2
Varnished timber mould = 2kn/m2
Rough timber mould = 3kn/m2
The value of adhesion to the mould is calculated by multiplying the area of the concrete in contact with the
mould by the adhesion factor = Area x Mould Adhesion Factor
Double T Beam should be calculated using 2 x deadweight and Coffered units should be 4 x deadweight.

Dynamic Loads
These should be calculated in most lifts of precast units, they are controlled by both the velocity and quality
of lifting equipment and the terrain being transported across.
The following factors should be used:
Demoulding = x 1.1
Turning = x 1.3
Site Transportation = x 1.5 (With a stationary crane)
Site Transportation = x 1.65 (Over even ground)

These are based on using overhead or static cranes at speeds of <=90m/min. For rough ground or when the site
installation details are not known, always use a factor of Dynamic Load ≥ x 2.
The true mass of a precast unit for anchor specification is worked out as follows:
(Demoulding) Mass = (Deadweight +Adhesion Factor) x Dynamic Load
(Transportation) Mass = Deadweight x Dynamic Load

Sling Angle
The angle is dependant on the length of chains / cables that are used to lift the unit. The shorter the chains
the greater the tensile load becomes on each anchor point. The following table show the factors by which the
pull factor should be calculated.
Angle β Pull Factor (z)
0º 1.00 β
z
15º 1.01 z

30 1.04
45º 1.08
60 1.16
90º 1.41
(Consult LFS for angles above 90º)


3

Calculation of Anchor Loads
(1) 2No. Load
Bearing Anchors
It is imperative to ensure that the load is distributed as evenly as possible
when deciding on the number of anchors and lift design.
z z

Thin walled panels and beams should be lifted and turned with two anchors
either with angled chains (1) or a spreader beam (2). This ensures even
load distribution across both anchors providing the anchors are set out
symmetrically either side of the centre of gravity. Please ensure that for
turning units that the correct extra reinforcement is observed.

For slab type units it is always advisable to use four anchors and a spreader
z
beam (3) to ensure even weight distribution. It is not possible to calculate
anchor loads for four anchors in panels as the exact distribution of load z
cannot be guaranteed (4) . Where the unit necessitates such a lift it is
essential to use an equalising device (5) that will distribute loads evenly
across all four anchors. The use of such a system must not only be available (2) 2No. Load
at all areas that the unit is lifted, but also used only by trained and Bearing Anchors
experienced persons. If any details of any part of the lift is not be available
then it should be taken that two anchors will be load bearing.
z β
A three point lift as show in (6) will always provide an even distribution of
z
load providing the anchors are spaced evenly and correctly around the z
centre of gravity. z

All demoulding should take place with a minimum concrete strength of (3) 4No. Load
15N/mm2 and ensuring that any load reduction factors are taken into Bearing Anchors
account. The safe working loads of all anchors are a minimum of three
times and two times for the concrete.
Anchor Loading
z
z β
To establish the actual anchor loadings, the following calculations are used:
Demoulding
Force / Anchor = (Dead Weight + Adhesion) x Dynamic Load x Pull Factor (4) 2No. Load
No. Anchors Bearing Anchors

Transportation
Force / Anchor = Dead Weight x Dynamic Load x Pull Factor
β
No. Anchors
z z
z
Example – 5m x 1m x 1m Beam. Area = 5m2 Deadweight = 12500kg z

Factory - Oiled steel mould, β = 15º, 2No. Anchors, Overhead Crane Only
Site Lift - β = 30º with Static Crane only (5) 4No. Load
2 Bearing Anchors
Demoulding = 12500kg + (5m x 1kN/m ) x 1.1 x 1.04 = 7436kg per Anchor
2
Transportation = 12500kg x 1.5 x 1.04 = 9750kg per Anchor
2 β
z
z
It is essential that the details in this literature are made available to all
120º
production staff and that they are aware of and understand the
installation instructions and safety regulations. z
LFS offer a full technical support service including design calculations and
on site pullout testing. Please contact us for further details.
(6) 3No. Load
Bearing Anchors


4

Capstan Transport Anchor System
The Capstan Transport Anchor system is a simple and effective system for lifting most types of precast concrete
unit. The anchors are forged from high grade steel and, provided the anchor is specified and installed
correctly, provides safe and secure lifting, turning and transportation of units. Anchors are available in black,
zinc plated, galvanised, 304 and 316 stainless steel
Each anchor is stamped on the head with the manufacturers identification and maximum load rating of the
anchor. Anchors are tested to a safety factor of at least three times their safe working load and 2.5 times
concrete failure when installed to the guidelines that follow. Lifting Shackles are proof loaded to twice their
safe working load and are supplied with a test certificate that is valid for six months from date of purchase.
Capstan Anchors are designed for demoulding, transport and site fixing. They should not be used for repeated
lifting applications.

Anchor Types

Capstan Transport Anchor Capstan Eye Anchor

1.3t—32.0t load groups and are 1.3t—32.0t load groups and use with a
suitable for large units such as reinforcement tail in thin walled units.
staircases, slabs, wall units, beams
and pipes.

Sandwich Panel Anchor Capstan Rod Anchor
1.3t—20.0t load groups and are 2.5t—15.0t load groups and are suitable
suitable for large sandwich panels for very thin precast units.
allowing vertical lifting.

Double Head Capstan Anchor Capstan Plate Anchor
1.3t—7.5t load groups and have 2.5t—10.0t load groups with a
been developed for automatic welded plate for production of
installation in concrete pipe thin slabs and demoulding
manufacture. These have also horizontally cast wall panels.
proved very effective for
Hollowcore production.


5


Capstan Anchor Accessories

Capstan Rubber Recess Former Capstan Fixing Screw
1.3t—32.0t load groups and are for 1.3t—32.0t load group and are for attaching
attaching the anchor to the mould the former through the mould. The screw
before casting. The former creates holds the anchor tightly to the formwork
a void in the precast to accept the when fastened with a washer and nut.
Shackle and to allow lifting through
360o.

Capstan Magnetic Recess Former Capstan Steel Recess Former and
Grommet
1.3t—10.0t load groups and are for
attaching the anchor to steel 1.3t—10.0t load groups and are for
moulds before casting. The former attaching the anchor to steel moulds
creates a void in the precast to before casting. The former creates a void
accept the Shackle and to allow in the precast to accept the Shackle and
lifting through 360o. to allow lifting through 360o. This part
requires a hole in the mould through
which a fixing screw is inserted and
fastened with a washer and nut.

Double Head Capstan Magnetic Recess Former
1.3t—10.0t load groups and are for attaching the anchor to the mould. The
former creates a void in the precast to accept the Shackle and to allow lifting
through 360o. They are available with either three or six magnets dependant on
the adhesion required. A rubber version for use in wooden moulds or for quick
release floating applications such as hollow core flooring is also available.

Capstan Lifting Shackle
1.3t—32.0t load groups and are for lifting and turning concrete units with
corresponding anchors cast in. The shackle head surrounds the anchor and can rotate
through 360o. Only the correct shackle for the anchor load group will fit.


6

Anchor Use and Specification Considerations
The LFS range of Capstan Transport Anchors are a simple and effective system for lifting most types of precast
concrete units. The anchors are manufactured from high grade steel and, provided the anchor is specified and
installed correctly, provides safe and secure lifting.
The anchors are designed as a method of demoulding, transportation and installation of precast units and
should not be used for repeated lifting. All anchors are tested by an independent institution to at least three
times safe working load and are supplied with batch numbers and certification on request. All shackles are
individually proof loaded to twice safe working load and supplied complete with certification on delivery. All
load table data is based upon a safety factor of 2.5 to 1 against concrete failure.
Anchor Operation
The Capstan Transport Anchor works by the distribution of load into the concrete via the tapered foot as shown
below, this provides high load values with short embedments in the concrete. The forces can even be
transferred into thin walled panels and safely lifted with the correct reinforcement.

It is essential to specify the correct length of anchor relevant to
Load Direction
the unit being lifted and the compressive strength of the
concrete at the time of lifting. This is a very important
consideration as reduced anchor loadings are experienced in low
strengths .
Installation
The anchors are installed in the formwork using one of a variety
of recess formers. These hold the anchors securely during
concrete pouring and create a void in which the shackle fits
after removal and once the concrete has cured. The anchor and Load transfers into the concrete in a cone
the recess will only accept the corresponding shackle rendering pattern and will breakout in this manner if
mismatching load groups impossible. overloaded

The anchors are available in various lengths for use dependant on the application required. In general, longer
anchors are to be used in thin panels or low strengths whereas short anchors are best in slabs and stronger
concrete.
It is essential that consideration is taken to ensure that the anchors are equally positioned around the centre of
gravity and that loads are distributed evenly between each anchor.
LFS offer a full technical support including calculations and on site pullout testing.
Please contact LFS for further details.


7

Installation Instructions for Panels and Beams
For vertical lifting of panels and beams the minimum edge distance required is as follows:
Edge Distance F = (Anchor Length A + Recess Depth E) x 3
These dimensions assume that the concrete is un-reinforced. Smaller edge distances are possible with suitable
reinforcement.
Walls and beams that contain only standard reinforcement shown overleaf should only be lifted at angles of
β ≤ 30o. If the loading on the anchors is reduced then the amount of reinforcement can be reduced.

E F
C

B A

D
Anchor Dimensions and Edge Spacing Required

Head
Length A Shank Dia. Foot Dia. D Head Recess Edge Distance F
Load Group Diameter
mm B mm mm Depth E mm mm
C mm
1.3t 120 10 19 25 10 390
1.3t 240 10 19 25 10 390
2.5t 140 14 26 35 11 450
2.5t 170 14 26 35 11 450
5.0t 240 20 36 50 15 765
5.0t 340 20 36 50 15 765
5.0t 480 20 36 50 15 765
7.5t 300 24 47 60 15 945
7.5t 540 24 47 60 15 945
7.5t 680 24 47 60 15 945
10.0t 340 28 47 70 15 1100
10.0t 680 28 47 70 15 1100
15.0t 400 34 70 85 15 1250
20.0t 500 39 70 98 15 1550
20.0t 1000 39 70 98 15 1550
32.0t 700 50 85 130 23 2150
32.0t 1200 50 88 130 23 2150

All other length variations have the same shank, foot and head dimensions. Special lengths are available to
order on request.


8

Load Capacities for Angled Lifting in Panels and Slabs
The table below is the permissible loads for axial or angled lifting in panels or slabs using Capstan Transport
Shackles. The maximum angle of lift is β = 30o.
10kn = 1 tonne of force
Load Direction
The table below assumes no edge reinforce- C
ment and the edge distances can be reduced
in reinforced concrete.
Other lengths of anchor are available.
A
Slabs should be designed to accommodate B
lifting moments during transportation.
10mm Min.
Main reinforcement is not required.

Min. Unit Edge Distance C Maximum Load Maximum Load
Load Group Length A mm
Thickness B mm mm 15N/mm2 25N/mm4

40 60 150 5 8
50 70 180 8 10
1.3t
65 85 225 13 13
85 105 285 13 13
2.5t 85 106 288 20 25
2.5t 120 155 393 25 25
85 110 300 24 36
5.0t 95 120 330 29 44
120 145 405 50 50
100 125 345 32 46
120 145 405 50 67
7.5t
140 165 465 68 75
165 190 540 75 75
115 140 390 44 65
135 160 450 62 77
10.0t
150 175 495 70 84
170 195 555 80 100
140 165 465 68 88
15.0t 165 190 540 78 111
200 225 645 113 150
200 225 645 113 150
20.0t
240 265 765 145 180
200 225 699 127 171
32.0t 250 283 819 180 210
280 313 909 220 240

β
z
z


9

Reinforcement Required for Axial Lifting
Minimum concrete strength = 15N/mm2

15º Max.

Please Note:

Where possible lifting angle should not exceed
30o.

Where mesh reinforcement is specified, an
equivalent amount of reinforcement steel or
smaller mesh with additional steel can be used.

Edge reinforcement steel should be 460 grade

1.3t and 2.5t anchors only require one layer of
mesh when minimum panel thickness is 60mm

Load Mesh Reinforcement Both Insert Stirrup Edge Reinforcement
Group Sides mm2/m Diameter mm
No. Diameter L1 mm
1.3t A142
Consult LFS
2.5t A142
5.0t A142 6 8 700 8
7.5t A252 6 10 1160 8
10.0t A252 6 10 1160 12
15.0t B503 8 10 1240 12
20.0t B503 8 10 1240 12
32.0t 2 x B503 8 12 1400 16


10

Load Capacities for Axial Lifting for Panels and Beams

Min. Unit
Length B Maximum Load Maximum Load Maximum Load
Load Group Thickness
mm 15N/mm2 20N/mm2 25N/mm2
d mm

60 13

1.3t 120 70 13 13 13

80 13

80 21 24

2.5t 170 100 24 25
25
120 25

100 43 49

5.0t 240 120 50 50
50
140 50

120 60 69

7.5t 300 140 67 75
75
160 75

10.0t 340 140 100 100 100

160 128 148

15.0t 400 180 142 150
150
200 150

160 166 191

180 182
20.0t 500 200
200 199 200

220 200

200 191 221 247

220 211 243 272

240 231 267 298

32.0t 700 260 253 292

280 275 318
320
300 299
320
320 320


11

Reinforcement Required for Angled Lifting
Minimum concrete strength = 15N/mm2

45º Max.

Please Note:

Where possible lifting angle should not exceed 30o.

Where mesh reinforcement is specified, an equivalent
amount of reinforcement steel or smaller mesh with
additional steel can be used.

Edge reinforcement steel should be 460 grade

1.3t and 2.5t anchors only require one layer of mesh
when minimum panel thickness is 60mm

Diagonal Lift
Insert Stirrup
Mesh Rein- Reinforcement
Edge
Load forcement
Reinf.
Group Both Sides
Diameter mm
mm2/m Diameter
B mm L mm No. Diameter L1 mm a mm
ds mm

1.3t 142 10 40 1900 8 10 680 100 10
2.5t 142 10 40 1900 8 10 680 100 10
5.0t 142 10 48 2100 8 10 940 125 12

7.5t 257 12 64 2100 8 10 1160 125 12

10.0t 257 16 140 2200 8 10 1160 125 12
15.0t 513 20 140 3900 8 10 1240 125 14

20.0t 513 20 140 3900 8 10 1240 125 16
32.0t 1026 25 175 4500 8 12 1400 125 16

12

Load Capacities for Angled Lifting for Panels and Beams
For angles greater than 30o please contact LFS. 10kn = 1 tonne of force

Min. Unit Maximum Load Maximum Load Maximum Load
Load Group Length B mm
Thickness d mm 15N/mm2 20N/mm3 25N/mm4

1.3t 120 95 13 13 13
100 25
2.5t 170 25 25
120 25
120 38 44 49
140 42 48
5.0t 240
160 46 50
50
180 50
140 42 48 54
160 47 54 60
180 52 60 67
7.5t 300 200 59 69
220 66
75
240 71 75
260 75
140 58 67 75
160 65 75 84
180 72 83 92
200 79 92
10.0t 340
220 84 98
240 90 100
260 95 100
280 100
160 79 91 102
180 88 102 113
200 97 112 125
220 107 124 138
15.0t 400
240 118 136
260 129 149
150
280 141
150
300 150
160 128 147 165
180 140 162 181
200 154 177 198
20.0t 500 220 168 194
240 182
200
260 198 200
280 200
200 147 170 190
220 167 187 209
240 178 206 230
260 195 225 251
280 212 245 247
32.0t 700 300 230 266 297
320 249 288
340 269 311
360 290 320
380 312 320
400 320

13

Capstan Eye Anchor
The Capstan Eye Anchor is for use when the transfer of load is not possible through the foot of a standard
anchor. This is usually for thin reinforced units or lightweight concrete. Reduced bond stress may need to be
considered for lightweight concrete.
The re-bar tail must be in close contact to the bottom of the hole to prevent concrete breakout when lifting.

C

H

G
B A

F
I

30o

E

J
D

Re-Bar Anchor Overall Anchor
Load Length Shank Dia. Head Dia. Foot Dia.
Hole Embedment Embedment Recess
Group A mm B mm C mm D mm
E mm F mm G mm H mm

1.3t 65 10 19 19 10 45 75 10
2.5t 90 14 26 27 13 64 101 11
5.0t 120 20 36 42 20 88 135 15
10.0t 180 28 47 57 25 136 195 15
20.0t 250 39 70 76 37 185 265 15

Reinforcement Specification
Unbent Re-bar Length I mm
Min. Unit Mesh
Concrete Compressive Strength
Load Group Thickness Reinforcement
mm Each Side Re-Bar Dia. J mm
15N/mm2 25N/mm2 35N/mm2

1.3t 80 A142 8 900 700 550
2.5t 80 A142 10 1350 1050 850
5.0t 100 A252 12 1900 1500 1200
10.0t 140 A252 20 2650 2050 1700
20.0t 160 A252 28 3750 2950 2400


14

Capstan Plate Anchor
The Capstan Plate Anchor is designed for reinforced concrete slabs too thin for a standard Capstan Anchor
which are lifted at right angles to its greatest dimension and for de-moulding panels.
The minimum panel thickness (J) is determined by the unit design by combining the anchor length, anchor head
recess and the specified cover. It is essential that not only the cover is observed but that the concrete can flow
freely under the base of the anchor to ensure corrosion resistance.

C

I

A G
A
B J
F H

Cover

DxE

Overall Anchor Permissible
Shank Head Plate Size Anchor Reinforcement Bars
Load Length Embed- Embed- Loads kN
Dia. B Dia. C D x E x F Recess
Group A mm ment ment
mm mm mm I mm
G mm H mm Length K 15N/ 25N/
Dia. J mm
mm mm2 mm2

2.5t 55 14 26 70 x 70 x 6 66 29 11 Dia. 8 x 4 200 10 15

2.5t 120 14 26 70 x 70 x 6 131 94 11 Dia. 10 x 4 300 25 25

5.0t 55 20 36 90 x 80 x 8 70 23 15 Dia. 12 x 4 450 30 40

5.0t 65 20 36 90 x 80 x 8 80 33 15 Dia. 12 x 4 450 40 50

5.0t 110 20 36 90 x 80 x 8 125 78 15 Dia. 12 x 4 450 50 50

10.0t 115 28 47 90 x 90 x 10 130 71 15 Dia. 16 x 4 600 80 100

J
L


15

Curved Capstan Transport Anchor
The Curved Capstan Transport Anchor is specifically designed for lifting, pitching and transporting sandwich
panels.
After installing the anchor head is positioned in the centroidal axis of the panel with the foot being central in
the load bearing layer which ensures a proper load transference. Spalling of the concrete during erection and
lifting is avoided with Curved Capstan Transport Anchors. A tilting table should be used to pitch units if
produced with only a front layer on top. Using connector pins close to the anchor is advisable.
These anchors should be used in conjunction with a spreader beam.

Load Direction
Load Direction

A

B

C

Min.Unit
Permissible
Load Group Length A mm Offset B mm Thickness C
Load Kn
mm

1.3t 277 50 13 80

2.5t 268 50 25 100

5.0t 466 60 50 100

7.5t 664 70 75 120

10.0t 667 70 100 140

15.0t 825 70 150 180

20.0t 986 90 200 200


16

Capstan Rod Anchor
The Capstan Rod Anchor is designed to pitch and lift very thin wall panels, reinforced girders or similar types of
unit as well as masonry wall units.
The anchor consists of a ribbed steel bar with a forged Capstan lifting head. The load is transferred into the
concrete by the ribs of the steel bar.
For special fabrications the bar can be bent in an offset manner to fit units such as sandwich panels.

B

A
G
C

E D F

Minimum Mesh
Total Rod Bar Anchor
Load Length Anchor Head Panel Permissible Reinforcement
Embedment Embedment Diameter Recess
Group A mm Dia. E mm Thickness Load kN Both Sides mm/
B mm C mm D mm G mm
F mm m2

2.5t 400 411 374 14 26 100 11 25 188

2.5t 520 531 494 14 26 100 11 25 188

5.0t 580 595 548 20 36 140 15 50 257

5.0t 900 915 868 20 36 140 15 50 257

7.5t 750 765 706 24 46 140 15 75 257

7.5t 1150 1165 1106 24 46 140 15 75 257

10.0t 870 870 885 28 46 160 15 100 257

10.0t 1300 1315 1256 28 46 160 15 100 257

15.0t 1080 1095 1015 34 69 200 15 150 257

15.0t 1550 1565 1485 34 69 200 15 150 257


17

Double Head Capstan Transport Anchor
The Double Head Capstan Transport Anchor has been specifically developed for use in pipe production where
anchor installation is automated. This permits high volume production by eliminating the manual operation of
fixing anchors.
The second head of the anchor assists accurate positioning and ensures perpendicular installation as it sits
tightly in the hollow of the former.
This feature also benefits the production of high volume flooring where large amounts of anchors are installed
on a regular basis. The rubber former is hard wearing and has a thread which allows quick removal and cleaning
with no requirement to remove excess concrete in the void. This anchor is lifted with the same shackle as
standard anchors.
B

Load Rating 1.3t 2.5t 4.0t 5.0t

40 85 95 95

50 120 170 100
Length (A) mm
65 - - 180
C
100 - - - A

Head Diameter (B) mm 19 26 36 36

Shank Diameter (C) mm 10 14 18 20

Permissible Loads for Double Head Capstan Transport Anchor
The concrete strength is for the time of first lifting.

Load Group Length (A) mm 25N/mm2 35N/mm2 45N/mm2
40 0.7t 0.9t 1.0t
50 1.0t 1.0t 1.0t
1.3t 65 1.3t 1.3t 1.3t
100 1.3t 1.3t 1.3t
120 1.3t 1.3t 1.3t
85 2.5.t 2.5.t 2.5.t
2.5
120 2.5.t 2.5.t 2.5.t
95 4.0t 4.0t 4.0t
4.0t
170 4.0t 4.0t 4.0t
95 4.0t 5.0t 5.0t
5.0t 100 4.0t 5.0t 5.0t
180 5.0t 5.0t 5.0t

Recess Formers
There are steel, magnetic and rubber formers available for Double Head Anchors. The steel formers are
designed for welding to the mould and have a magnetic insert to keep the anchor in place when casting.
Magnetic formers are also steel and have magnets in the base to securely attach to the formwork.
Rubber formers work in the same manner but have a metric screw thread in the base to attach through wooden
formwork for quick removal from cured concrete with a floating application.

Magnetic Former The second head sits
flush with the base of
the former.


18

Double Head Capstan Transport Anchor
Use with Hollowcore Flooring Manufacture
The Double Head Capstan Transport Anchor is a very effective method of demoulding, lifting and installation of
most types of Hollowcore flooring panels.
The anchors are installed in extruded or slip formed Hollowcore by collapsing the cores at the required lifting
points and back filling with a suitably wet mix of the same concrete to the top of the panel. Larger sizes of
cores may require the use of a Slab Cap or semi-dry mix inside the core either side of the lifting point. The
concrete should be compacted well without damaging the webs, taking care that the recess is completely
filled.
The anchor should be worked down in the poured concrete until the former is flush with the top of the panel
ensuring no possibility of air gaps and trowel around the former for a neat finish.
It is recommended that, where possible, demoulding Hollowcore should be carried out using clamps or ensuring
that the concrete is sufficiently cured to support the load required for the lift.
With most Hollowcore applications, the edge distances that are achievable are less than would be expected for
obtaining full lifting loads in unreinforced concrete. However, as the deadweight of the units are greatly
reduced by the cores or polystyrene, the loads on each anchor is reduced resulting in effective lifting with
relatively small edge distances.

Because there are large variations in the concrete mixes, reinforcement
strand patterns and lifting intentions, it is imperative to ensure that the
anchor and installation is correct for each application. LFS offer a
complete design and technical support service for customers wishing to
implement the Double Head Anchor system into their production. This
service includes load calculations, anchor specification, training and an
on-site service to test the load capabilities in concrete panels. Our test
unit has a 25.0t capacity for both proof and destructive loading of
anchors. This testing includes both initial set up and periodically
arranged visits to monitor the continuity of achievable loads. This test-
ing is backed up by a full report of results and technical support for
customers working in partnership with LFS.

Lifting with Double Head Anchors
The Double Head Anchor uses the same shackle as standard Capstan Anchors. LFS recommend that clients using
this system should fully convey the permitted lifting design to their customers, for example, many installations
are intended for final positioning only. It is imperative that the installation teams are fully aware of such
arrangements.

When all site lifting requires use of Double Head
Anchors, the use of a Safety Lifting Rig is
recommended. The rig is constructed as shown
opposite and is designed to offer complete
security with safety chains under the panels and
exact load distribution between each anchor by
use of an equalising plate.
Safety Lifting Rigs are designed for panels up to
10.0t and can be manufactured specific to
customer requirements. These are supplied with
test certificates and are available for both sale
and hire at daily and weekly rates.
Please contact LFS for all sale, hire and technical
information.

19

Capstan Lifting Shackles
The Capstan Shackle is the attachment used for lifting, turning and transportation of concrete units with the
corresponding anchors cast in. This is a manually operated device which is available in 1.3t—32.0t load groups.
Each shackle is proof loaded to twice safe working load at a recognised independent test institution and
supplied certified and index numbered for traceability when supplied new. All health and safety regulations
and suitable risk assessments should be observed when using LFS lifting shackles and site lifting equipment.

Crane Hole Width Crane Hole Height Anchor Aperture
Load Group Overall Length (mm)
(mm) (mm) (mm)

1.3t 188 40 68 11
2.5t 230 50 86 16
4.0t - 5.0t 283 70 88 21
7.5t - 10t 401 90 115 30
15.0t - 20.0t 506 140 135 41
32.0t 680 160 189 52
Using Capstan Lifting Shackles

Engaging
Select the correct shackle and place the head opening over the anchor
and lower the weighted lip down onto the concrete as show in Fig. 1.
The shackle will now be ready for use.

Lifting
Once the shackle is engaged the unit can be lifted. The direction of lip
must always be in the direction of the lift as this locks the shackle under
load. The shackle is suitable for axial / angled lifting, turning, pitching
and swivelling of units providing the anchors have been suitably
reinforced. Please observe the maximum lifting angles per the design
which should be supplied by the manufacturer or engineer.

Releasing
Once the lift has been completed and the load has been removed the Lift Direction
shackle can be released by moving the lip towards the handle. Always
ensure that the shackle is clear of the recess before withdrawing the Lift Direction
crane. Fig
Maintenance
Shackles should be checked for damage prior to each lift and inspected Weighted lip
by a qualified engineer every six months and recorded appropriately. must always
be in the load
The maximum life of a shackle under constant use is seven years
direction
provided the limited dimensions are not exceeded. Any modifications or
repairs are strictly prohibited.

Max Aperture Min. Aperture
Load Group
Width (mm) Thickness (mm)
1.3t 13 5.5
2.5t 18 6
4.0t - 5.0t 25 8
7.5t - 10t 32 12
15.0t - 20.0t 46 18
32.0t 58 24

20

Capstan Recess Formers
The Capstan Anchor must be installed in the unit using the correct former for the anchor and application. This
will provide quick and secure installation and form a recess for the shackle. Only the correct former will fit the
anchor and the load group is marked on each one. The former can be used by floating in the concrete or by
bolting through the formwork or by magnets. The formers are available in recyclable rubber and steel in load
groups from 1.3t to 32.0t.

Rubber Formers
The rubber former is resistant to oil and retains its shape in temperatures up to 120 oC. The former is reusable
many times if correctly used and cleaned after each use. Mould oil should be applied to the former before the
anchor is inserted.
Short sided formers are also available and are for use when lifting thin panels.

Floated Installation
With this application the concrete is poured first and the anchor is installed once the fill level has been
achieved. The anchor is inserted into the concrete until the bottom of the former is touching the concrete
which should then be vibrated until the top is flush with the concrete. At its final position the anchor much be
perpendicular to the base of formwork. It is advisable to use a fixing screw and a wooden block to ensure the
former is tightly shut to prevent any concrete ingress.

Removal of Former
When the concrete has cured the former is simple to remove. If a fixing screw has been used, remove this first
and, with two pieces of reinforcement bar, use a scissors action to release the former from around the anchor
and lift the former clear. If there is any excess concrete in the recess this should be removed before lifting.

Installation with Fixing Screw
When installing through wooden formwork a fixing screw or nut is required. If the
sides of formwork can be removed in a horizontal direction then a fixing screw
can be used. When this is not possible then a separate fixing nut and screw is
required. These are available in all load groups.


21

Steel Recess Formers
The Capstan Anchor can be installed in metal formwork by the use of a steel formers.
These is used where the lifting anchors are not accessible when casting. They are
available in load groups from 1.3t to 20.0t. All steel formers are zinc plated for
corrosion resistance.
Using Steel Formers
The former is first attached to the mould by either its thread or by welding. The
anchor is then placed in the centre of the former and the rubber sleeve put around
the shank and pushed into the void, holding it tightly in position. The former and
sleeve should be coated in mould oil before casting. When the unit is struck the
former remains on the mould with the anchor and sleeve coming away with the unit.
The sleeve should then be removed and cleaned for reuse.

When installing using steel formers, particularly when the anchors are horizontal to the formwork, provisions
should be made to ensure it remains fixed during pouring. This can be done by tying the anchor to the form-
work or by using spacers.
Magnetic Formers
The steel formers are also available with magnets installed in the base to allow the attachment of anchors at
any required point in a steel mould. These have either three or six magnets in the base and should be chosen
dependant on the adhesion required when casting. Larger units with a heavy concrete flow should use the
higher adhesion. The rubber sleeve should be used in the same manner as standard steel formers.

Anchor Load Concrete
Adhesion (kp) Ø (mm)
(t) Cover (mm)

1.3 50 60 10
2.5 50 74 11
3.5 100 74 11
5.0 50 94 15
5.0 100 94 15
5.0 120 94 15
5.0 180 94 15
10.0 50 118 15
10.0 100 118 15
10.0 120 118 15
10.0 180 118 15


22

Utility Anchors
The Utility Anchor is designed for reinforced or unreinforced concrete units and are especially useful for cover
slabs, pipes and culverts or any application where the construction site can benefit from an approved and
tested lifting anchor that can be used with a crane hook and no other special lifting device.
Benefits of Utility Anchors

• Economical alternative for de-mould, handling and installing precast units.

• Versatile system that can be used for most types of precast unit.

• Lifting capacity of up to 7500kg.

• Easy to install.

Utility Anchor Components

Fixing Screw
Wet Setting Plate


23

Utility Anchors
Installation Instructions for Precast Units

Placement of Utility Anchors
This can vary dependant on the structural shape of the units
and the manufactures or engineer’s preferences. Utility
Anchors are not designed for thin edge applications. Always
ensure that the minimum edge distances are maintained and
that lifting design takes into consideration the minimum
strengths as noted in the capacity chart along with any other
dynamic forces.
It is recommended that the formers should always be placed in
line with the load direction of lifting chains.

Typical Installations
Wet Setting
1) Assemble the anchor, former and
either a Fixing Screw or Wet
Setting Plate
2) If required, use grease or duct
tape for an extra seal for the
cavity in the former.

3) Work the assemble into the wet concrete until the top surface of the former is flush to the concrete.
Ensure that any air bubbles are removed before setting is complete.

Fixing Screw Setting
1) Assemble the anchor and former.
2) If required, use grease or duct tape for an extra seal for the cav-
ity in the former.
3) Drill a hole in the formwork at the installation point and attach
the assembly with the fixing screw and the thread cast into the
former.
4) Ensure that any air bubbles are removed before setting is
complete via vibrating poker or similar method.

Fixing Plate Setting
1) Assemble the anchor and former.
2) If required, use grease or duct tape to seal the cavity in the
former.
3) Screw or nail the fixing plate to the formwork at the installation
point and place the assembly on the pins and push firmly into
place.
4) Ensure that any air bubbles are removed before setting is
complete via vibrating poker or similar method.


24

Utility Anchors

Min Panel Min Edge
Product Tension Shear SWL
A B C Thickness Distance
Code SWL Kg Kg
mm mm

LF01UA08135 80 134 11 800 1300 102 160
LF01UA20095 95 152 11 1800 2500 114 190
LF01UA25120 120 181 11 2000 3000 140 240
LF01UA35170 170 238 11 2500 3500 203 340
LF01UA14080 80 135 17 1400 1800 102 160
LF01UA35095 95 173 17 3500 5000 114 190
LF01UA50120 120 188 17 5000 7000 140 240
LF01UA75170 170 254 17 7500 8500 203 340

Utility Anchor Former

Product Code C D E

UAF200 203 76 89


25

Utility Anchors
Angled Lifting
The safe working load figures on Page 25 are based on straight chains providing a pure tension lift. For angled
lifting applications, please reduce the design lifting capacity by the figures quoted in the table below. Dynamic
factors for transport will also apply as detailed on Page 3 of this manual.

Sling Angle Load Factors

Sling Angle β 120o 105o 90o 75o 60o 45o 30o 15o

Load Factor 2 1.64 1.41 1.26 1.16 1.08 1.04 1.01

Adjusting Loads for Concrete Strength
The safe working loads detailed on Page 25 are based on a concrete compressive strength of 25N/mm2 and is
quoted for tensile applications. Please consult LFS for any special requirements in shear below this strength.
To convert the allowable load in tension for an unreinforced anchor from a concrete strength of 25N/mm2 to a
greater or lesser concrete strength, multiply the safe working load at 25N/mm2 by the applicable factor listed
below.

Concrete Strength Adjustment Factors

Increased Concrete Strength
30N/mm2 Multiply SWL by 1.13


Increased Concrete Strength



26

Lifting Sockets and Inserts
Flat End and Cylindrical Lifting Sockets provide simple lifting and transporting for most kinds of precast
concrete units, particularly when casting into thin concrete panels. Flat End Lifting Inserts are available in
both high grade zinc plated carbon steel and 303 grade stainless with metric threads. Cylindrical Sockets
are also available in both materials and also Rd and metric type threads. All installation instructions are
based on a 2:1 concrete safety factor at a strength of 15N/mm2 and 3:1 for steel inserts and are tested
for by a recognised institution. Flat End and Cylindrical Lifting Sockets can be used in conjunction with
Plastic Nailing Plates or Magnetic Holding Plates to provide a 10mm recess that can be made good on site.
Plastic Stopper Caps are also available to protect threads from weathering.
Please contact LFS with any technical queries.
F
B

H

D

A E

Plastic Stopper to
C prevent concrete
ingress
G

Cylindrical Lifting Sockets Flat End Lifting Sockets

Overall Usable Overall
Axial Load Size (Thread x Rebar Hole Size (Thread x Rebar Hole Usable Thread
Diameter Thread Load Rating Diameter
Rating Length A) Size (C) Length E) Size (G) Length (H)
(B) Length (D) (F)

500kg M/Rd 12 x 40 15 8 22 500kg M12 x 60 15 10 22
500kg M/Rd 12 x 48 18 10 25 1200kg M16 x 80 21 13 27
1200kg M/Rd 16 x 58 21 13 27 1200kg M16 x 100 21 13 27
2000kg M/Rd 20 x 70 27 16 35 2000kg M20 x 95 27 16 35
2500kg M/Rd 24 x 80 31 17 43 2500kg M24 x 110 31 18 43
4000kg M/Rd 30 x 101 39 22 56 4000kg M30 x135 39 22 56
6300kg M/Rd 36 x 125 47 25 69 4000kg M30 x150 38 22 56
8000kg M/Rd 42 x 140 54 30 80 - - - -
12500kg M/Rd 52 x 170 72 40 97 - - - -

Anchor Spacing
The following should be observed for all anchor installations and should also have sufficient
C/L
reinforcement as detailed on the next page.

Axial Load Edge Distance Edge Distance
Size
Rating A mm B mm
A B
500kg M/Rd 12 37 300
B/2
1200kg M/Rd 16 40 400

2000kg M/Rd 20 50 550

2500kg M/Rd 24 60 600

4000kg M/Rd 30 70 650

6300kg M/Rd 36 100 800 B
8000kg M/Rd 42 120 1000
A B/2
12500kg M/Rd 52 138 1200 3xA

27

Axial Lifting
All Sockets and Inserts must be reinforced for lifting with BSt500s reinforcement bar as per the table and
sketches below. Reinforcement around the anchor can be in the form two layers of mesh or a re-bar cage
befitting the unit as specified by the design engineer. The socket reinforcement can be in the form of a 60º
angled bar (1) or with parallel ‘U’ bars (2). For slab type units the reinforcement can be cranked down from
the ‘U’ bar to fit the thickness of the panel (3), straight bars must not be used and extra bars must be laid
across the flats of the bar. Mesh reinforcement is essential.

Min. Mesh
Axial Load Leg Length Leg Length Bar Diameter Internal Diameter
Size Reinforcement
Rating (L1) mm (L2) mm (BD) mm (ID1) mm
(Two Layers)

500kg M/Rd 12 230 190 6 24 Q131

1200kg M/Rd 16 320 280 10 40 Q131

2000kg M/Rd 20 440 380 12 48 Q131

2500kg M/Rd 24 475 410 12 56 Q188

4000kg M/Rd 30 650 570 16 64 Q188

6300kg M/Rd 36 820 720 20 140 Q188

8000kg M/Rd 42 850 730 25 175 Q188

12500kg M/Rd 52 1200 1020 25 196 Q188

(2) (4)
(1)

ID1 ID2
L1
ID1 L2
BD (3) L3
BD 30º BDH
60º L3

For angled lifts it is essential to reinforce the socket to ensure the load is distributed into the concrete unit,
for angles of greater than β = 12.5º the following reinforcement should be observed and installed in the panel
as in (5) with a re-bar hanger as detailed in (3). If this pattern is used straight bars should be laid over the
cranked bars at right angles. The axial pull reinforcement must be in contact with the base of the socket (6).

(5)
Internal
Axial Load Leg Length Bar Diameter
Size Diameter β
Rating (L3) mm (BDH) mm B
(ID2) 10mm

500kg M/Rd 12 150 24 6
20º
1200kg M/Rd 16 200 32 10
(6)
2000kg M/Rd 20 300 32 12

2500kg M/Rd 24 300 40 14

4000kg M/Rd 30 400 48 16

6300kg M/Rd 36 550 56 20

8000kg M/Rd 42 600 64 25

12500kg M/Rd 52 750 140 28


28

Pitching / Turning
Lifting Sockets and Inserts are designed to be used in thin panel applications for turning through 90º from
horizontal to upright. All Sockets and Inserts must be reinforced for lifting with BSt500s reinforcement bar as
per the table and must include the extra reinforcement as detailed below.

Internal
Axial Load Leg Length Leg Length Bar Diameter Bar Diameter Internal Diameter Height
Size Diameter
Rating (L1) mm (L2) mm (BD1) mm (BD2) mm (ID1) mm (h) mm
(ID2) mm

500kg M/Rd 12 270 280 6 8 24 24 35

1200kg M/Rd 16 350 400 8 12 32 32 49

2000kg M/Rd 20 500 500 10 14 40 40 64

2500kg M/Rd 24 520 560 12 14 48 48 75

4000kg M/Rd 30 580 590 12 16 48 48 92

6300kg M/Rd 36 700 700 14 16 56 56 118

8000kg M/Rd 42 850 860 16 20 64 64 143

12500kg M/Rd 52 950 1000 20 20 140 140 174

L2
ID1

Lift Direction

BD2 15º

ID2
H
BD1

L1

For turning or erecting units through 90º as detailed below, only half the weight of the unit is being lifted and
therefore there is no reduction in the safe working load of the anchor and the same permissible loads and
standard sling angle reduction factors apply. However, for lifting at these angles the permissible load per
anchor is half the axial load rating. Sling angle factors apply to the chains in the same manner as axial lifting.
Combination Lifting Loops or Swivel Eyes should always be used for turning or pitching units.

Load Direction

z
z β


29

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