Cable tensions in multi-insert rigging systems for tilt-up panel lifting

Abstract In tilt-up construction, cable and pulley systems (riggings) are used to lift precast panels from horizontal to vertical positions. Accurate prediction of cable tensions is essential for structural integrity and operational safety. This study develops a generalized nonlinear system of equations to model diverse rigging configurations for tilt-up erection. A dynamic analysis is included to evaluate the influence of crane hook velocity on cable tension. The equations are solved using MATLAB’s symbolic “solve” function, and a dynamic factor is introduced to quantify inertial contributions across operational scenarios. Validation was performed through simulations in Working Model software. Results show that the dynamic factor significantly affects cable tensions at moderate to high lifting velocities, particularly beyond 75° of rotation, while at lower velocities it increases static tensions by 1.33–1.59 times depending on panel height. To mitigate overload risks, the effect of hook inclination was analyzed, identifying a safe range between 85° and 95°. The formulation accommodates both aligned and misaligned inserts, covering multiple rigging layouts with 1–8 rows and 1–8 columns. This approach provides a foundation for more advanced computational tools, enhancing accuracy and safety in tilt-up panel erection.