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To meet the requirements of tight deadlines, cost reduction, and consistent high quality, the use of industrialized or “precast” structural elements has become the preferred solution In the construction sector.
In this context, precast construction materials by Copac stand out as leading solutions for ensuring safety and streamlining on-site assembly.
For construction companies, precast manufacturers, or assembly specialists, Copac provides assistance through a range of high-tech equipment designed to meet the specific requirements of precast concrete (precast slabs, walls with integrated formwork, columns, and beams).
Industrialized construction methods and their safety challenges
Off-site or precast construction requires millimetre-level precision. Unlike traditional casting, the assembly of precast elements requires an immediate stabilization and adjustment phase. The challenge is no longer just to formwork, but rather to support, adjust, and protect elements which weight several tons as soon as they are set down by the crane.
Copac products for precast construction address three major challenges:
Equipment Solutions
BEAM FORMWORK SYSTEMS
Horizontal Formwork: The Copac Beam Formwork System
In industrial construction, the production of reinforced concrete beams requires equipment capable of ensuring perfect geometry and high productivity. The Copac Beam Formwork System is a benchmark solution for companies seeking to combine technical performance and collective safety when forming horizontal structural elements.
Designed to adapt to the constraints of every project, our beam formwork system stands out through several key advantages:
- Modularity and Precision Adjustment: Thanks to a system of jacks and bolted frame extensions, our formwork systems can adapt to all beam lengths and cross-sections. Fine adjustment allows compensation for irregularities in the supporting surface and ensures perfect alignment of the structure.
- Integrated Workstation Safety: The Copac Beam Formwork System incorporates collective protection equipment (CPE) as standard. The installation of guardrails, end safety gates, and access staircases ensures worker safety throughout all phases: reinforcement installation, concrete pouring, and striking.
- Load-Bearing Brackets and Watertightness: The external side panel load-bearing bracket system ensures the stability of the side panels. This rigidity prevents deformation under concrete pressure and guarantees watertightness by preventing cement slurry leakage and ensuring a high-quality concrete finish.
Technical and Commercial Support on Site
Because the performance of a beam formwork system depends on proper installation, Copac’s support goes beyond simply supplying equipment. Our commercial and technical teams provide direct on-site assistance during the initial installation of the equipment. This start-up assistance service ensures the correct operation of the formwork system, trains your teams in precision adjustments, and optimizes your production cycles from the very first use.
By integrating safety into the formwork design, the Copac Beam Formwork System secures your concrete pouring operations and allows your teams to focus on execution quality.
MANUAL HANDLING FORMWORK
Manual Handling Formwork Systems
In precast construction, cranes are often fully occupied lifting heavy elements (precast slabs, wall panels, etc.). For secondary formwork operations, such as joints between elements, connecting columns, or parapets, Copac offers manual handling formwork solutions.
These ultra-lightweight systems help maintain high productivity while preserving worker health:
- Lightweight and Ergonomic: Designed in aluminium, timber-faced panels, or high-strength composite materials, our manually handled panels can be operated by a single worker. This reduced weight significantly limits exposure to Musculoskeletal Disorders (MSDs) and allows structural node formwork operations to progress without monopolising the crane.
- Fast Assembly: Thanks to an intuitive locking system and integrated accessories, assembly and striking can be carried out in record time. This is the ideal solution for formwork of precast joints or small in-situ concrete walls that ensure the structural continuity of the building.
- High-Quality Concrete Finish: Despite their lightweight design, our manual handling formwork systems guarantee excellent rigidity under concrete pressure. They provide an impeccable concrete finish, making subsequent finishing and painting operations easier.
By integrating Copac’s manual handling formwork systems into your precast construction projects, you optimise your production cycles and provide your teams with versatile equipment that is easy to transport and install in confined spaces.
Stabilisation and Support: Push-Pull Props
In precast construction, shoring is not limited to supporting vertical loads. It is primarily a matter of lateral support and plumb adjustment. Once installed, precast elements require immediate and reliable stabilisation to ensure the geometry of the structure and the safety of workers.
Push-Pull Props: The Pillars of Assembly
Push-pull props are essential equipment for precast construction. Designed to stabilise wall panels (double walls, integrated formwork walls, and precast wall panels), they provide highly accurate adjustment thanks to their double-thread micrometric adjustment system.
Securing Precast Slabs and Hollow-Core Slabs
The installation of precast slabs or hollow-core slabs is a high-productivity operation. While it provides significant time savings, it immediately exposes workers to fall hazards around the entire perimeter of the building. Safety measures must therefore be implemented just as quickly as the installation itself.
Guardrails Mounted on Lifting Anchors
The guardrail post system mounted on lifting anchors is one of the most widely used Copac products for precast construction. Its strength lies in its fixing method, which uses the built-in lifting anchors of the concrete element itself.
Slab Clamps and Edge Protection Systems
For precast elements that do not feature accessible lifting anchors, such as hollow-core slabs or solid slabs, Copac offers mechanical clamping solutions.
Monobloc Guardrails for Precast and Hollow-Core Slabs
For projects requiring high installation rates, Copac offers monobloc guardrail systems. This solution integrates the safety post and the fixing base into a single, inseparable unit, specifically designed for precast floor systems.
WINNER OF THE 2025 MAT D’OR AWARD – “INNOVATION”
THE PODIFLEX ADJUSTABLE PODIUM FOR PRE-DESIGNED OPENINGS
Even within an industrialised construction process, openings (lift shafts, service shafts, stairwells) remain areas exposed to fall hazards. In the case of precast lift shafts, safety measures must be implemented immediately to allow the construction sequence to continue without interruption.
Copac addresses this challenge with the PODIFLEX Adjustable Podium, a solution designed for flexibility and total protection.
An Adaptable and Robust Working Platform
The PODIFLEX Adjustable Podium is an adjustable platform installed directly inside lift shafts or pre-designed openings. Its strength lies in its ability to provide a stable working deck where standard solutions are often difficult to implement.
Thanks to its locking system and ease of transfer from one level to another, the PODIFLEX Adjustable Podium integrates seamlessly into the logistics of precast construction projects, transforming a hazardous area into an ergonomic workstation.
Handling and Lifting: Securing the Transfer of Elements
Precast construction is, above all, about logistics. Between the arrival of delivery trucks and final installation, equipment must be transferred smoothly and safely. Copac provides handling and marking solutions that structure the flow of materials between the storage area and the installation zone, ensuring an organised site with no risk of damage.
PRESERVATION AND SAFETY
Optimising Storage and Protecting Equipment
A high-performing precast construction site is one where every accessory has its place. Our storage baskets for push-pull props are designed to meet this organisational requirement:
- Equipment protection: By avoiding bulk storage, you protect the threads and micrometric adjustment mechanisms of your props.
- Safe lifting operations: Transporting accessories in secure baskets eliminates the risk of falling objects during lifting operations and makes the work of riggers easier.
- Copac designs and manufactures dedicated storage baskets tailored to your actual needs. We develop custom-made handling solutions on demand (including the preparation of a design specification). This personalised approach guarantees optimal organisation in your production area.
CONTROLLED INDUSTRIAL PROCESS
Defining Lifting and Overhead Load Zones
The lifting of heavy elements (precast slabs, integrated formwork walls, etc.) requires strict management of hazardous areas. Copac provides robust zone protection solutions to secure the working environment:
- High-visibility site barriers: Used to physically define suspended load zones and prevent access to handling areas during critical operations.
- Structured site marking: These solutions help organise temporary storage areas, ensuring smooth movement of handling equipment and ground crews.
By integrating logistical solutions, you transform handling constraints into a controlled industrial process, where safety accompanies every lifting operation.
Our precast construction projects
Copac’s Expertise
Design Office and On-Site accompaniment
Industrialized construction demands requires a high level of precision, with no room for improvisation. Copac’s expertise lies in its ability to integrate safety and stability right from the design phase of your project.
Layout study: Safety Through Calculation
For each worksite, our design office conducts an in-depth analysis of the specific constraints related to your structural elements. By determining the weight of the precast walls, wind loads, and available anchor points, our engineers calculate the exact number and strategic placement of the necessary push-pull props. This layout plan then becomes an essential reference document for the site manager, as it certifies that the installation strictly complies with regulatory calculation notes.
Just-in-Time Logistics: Off-Site Synchronization
Thanks to our strategic geographic network, we ensure the delivery of your equipment in coordination with your precast plant’s schedule. This logistical synchronization allows us to deliver materials “just in time” for installation, freeing up your manoeuvring areas and avoiding unnecessary clutter on-site. By optimizing material turnover in this way, Copac contributes to reducing your idle inventory and accelerate your production cycles to optimize profitability.
Business Synergies
Precast construction is a complex ecosystem. Copac offers complementary solution to suit your specific needs, beyond the traditional pre-industrialized “reinforced concrete” solutions, such as:
- For major renovation or repurposing projects that require underpinning, explore our section dedicated to Renovation.
- If your methodology relies on traditional in-situ casting cycles with a need for work platforms, check our tailored-built solutions for New Construction.
FAQ: Questions About Copac Products for Precast Construction
Which Copac products are essential for assembling precast walls?
Push-pull props for stabilisation and plumb adjustment are the priority.
How do you secure a precast slab immediately after removal?
Copac offers dedicated guardrail posts that are anchored directly to the lifting anchors or fixed using slab clamps, providing immediate perimeter protection.
Are Copac push-pull props suitable for high wind loads?
Yes. Our products are supported by detailed structural calculations. Our engineering office designs the shoring system according to the exposed surface area of the precast element and the geographical wind zone.
How do you use Copac equipment to adjust the plumb of a precast column?
Using two push-pull props installed at 90° allows millimetre-accurate vertical alignment thanks to the precision adjustment sleeves.
Is the PODIFLEX podium usable in precast elevator shafts?
Yes, this is one of its main applications. It allows the opening in the shaft to be covered as soon as the element is installed, thereby securing the lower levels.
Are your products compliant with current safety standards?
All Copac products for precast construction comply with current French and European standards (including NF P93-351 for working platforms).
How can I request a layout plan for shoring my walls?
Contact our engineering office with your precast element installation drawings. We will carry out a bespoke study, including support reaction calculations.
Build with Complete Peace of Mind
by using Precast Construction
Choosing Copac products for precast construction means opting for safety without ever reducing the speed of execution. The industrialized construction industry requires partners capable of keeping pace with the fast-paced factory environment while ensuring flawless precision on-site.
At Copac, we empower construction professionals to tackle challenges with confidence, so they can focus on what matters most: building the future with efficiency and peace of mind.
