Concrete Pouring and Formwork Installation Safe Work Procedure
Document Number: [SWP-NUMBER]
Revision Date: [DATE]
Next Review Date: [NEXT REVIEW DATE]
Department: [DEPARTMENT NAME]
1. Scope
This Safe Work Procedure (SWP) outlines the safety requirements for concrete pouring and formwork installation. It includes hazard identification, risk assessment, and control measures to ensure compliance with safety regulations.
2. Definitions
Formwork The total system of support for freshly placed or partially cured concrete, including the mold or sheeting (form) that is in contact with the concrete as well as all supporting members including shores, reshores, hardware, braces, and related hardware. [3] [7]
Falsework Formwork to support concrete and placing operations for supported slabs of concrete structures, including all supporting members, hardware, and bracing. [3]
Reinforced Concrete A composite material in which the concrete provides the material's compressive strength, while the forcing in the form of additional embedded material provides the tensile strength and/or ductility. [3]
Competent Person One who is capable of identifying existing and predictable hazards in the surroundings or working conditions which are unsanitary, hazardous, or dangerous to employees, and who has authorization to take prompt corrective action to eliminate them. [3]
Dead Load A constant load, without load factors, due to the mass (weight) of members, the supported structure and permanent attachments or accessories. [3]
3. Responsibilities
3.1 Supervisors
- Ensure all workers are properly trained and competent to perform their assigned tasks.
- Conduct regular site inspections to identify and correct hazards.
- Enforce all safety procedures and ensure workers comply with them.
- Provide necessary PPE and ensure it is used correctly.
- Ensure formwork is inspected by a professional engineer or competent worker before concrete placement.
3.2 Workers
- Follow all safety procedures and instructions.
- Use required PPE correctly and report any defects.
- Report any hazards or unsafe conditions to the supervisor immediately.
- Participate in pre-job briefings and toolbox talks.
- Do not place any construction loads on a concrete structure unless authorized by a qualified person.
4. Potential Hazards and Risks
| Hazard | Risk | Control Measures |
|---|---|---|
| Eye, skin, and respiratory tract irritation [1] [4] | Exposure to cement dust can cause irritation and burns. | Wear appropriate PPE, including safety goggles, alkali-resistant gloves, and respiratory protection. Wash exposed skin immediately with clean water. |
| Slips, trips, and falls [1] [4] | Wet concrete and job site debris can create slip and trip hazards. | Maintain good housekeeping practices. Clean up spills immediately and remove debris. Wear slip-resistant footwear. |
| Manual handling injuries [1] [4] | Lifting heavy materials can cause strains and sprains. | Use proper lifting techniques: keep your back straight, bend your knees, and keep the load close to your body. Use a buddy system or mechanical aids for heavy or awkward loads. |
| Struck by equipment [4] | Workers may be struck by concrete pump trucks or other equipment. | Use a spotter to direct equipment operators. Establish clear communication signals. Wear high-visibility clothing and hard hats. |
| Formwork collapse [1] [8] | Improperly constructed or overloaded formwork can collapse. | Ensure formwork is designed by a qualified person and erected according to the design. Inspect formwork before and during concrete placement. Do not overload formwork. |
| Impalement [1] | Unprotected rebar can cause impalement injuries. | Guard or cap all exposed rebar. Use caution when working around rebar. |
| Electrical hazards [2] | Using power tools near wet concrete can cause electrocution. | Use ground fault circuit interrupters (GFCIs) with all electrical equipment. Keep electrical cords away from wet areas. Inspect cords for damage before use. |
| Falling from heights [1] | Working at heights without fall protection can result in serious injury or death. | Use guardrails, safety nets, or personal fall arrest systems when working at heights. Ensure scaffolds are properly erected and inspected. |
5. Personal Protective Equipment (PPE)
Proper PPE must be worn at all times when performing concrete pouring and formwork installation work to protect against hazards such as chemical burns, eye injuries, and respiratory irritation.
- Hard Hat: Provides head protection from falling objects and impacts.
- Safety Glasses/Goggles: Protects eyes from cement dust, flying particles, and splashes. [1]
- Alkali-resistant Gloves: Protects hands from chemical burns and skin irritation caused by wet concrete. [1]
- Waterproof Boots: Protects feet from wet concrete and provides slip resistance. [4]
- Long-sleeved Shirt and Pants: Protects skin from contact with wet concrete and cement dust. [1]
- Kneepads: Protects knees when kneeling on fresh concrete. [4]
6. Equipment and Tools
All equipment and tools used for concrete pouring and formwork installation must be inspected before each use to ensure they are in good working condition.
- Concrete Mixer: Used to mix concrete ingredients. Ensure it is properly guarded and maintained.
- Concrete Pump: Used to pump concrete to the desired location. Inspect hoses and connections before use.
- Vibrator: Used to consolidate concrete in forms. Ensure it is in good working condition.
- Hand Tools (shovels, rakes, floats): Used for placing and finishing concrete. Keep tools clean and in good repair.
- Wheelbarrow/Concrete Buggy: Used to transport concrete. Do not overload.
7. Pre-Job Requirements
7.1 Training and Competency
Training and Competency: All workers must be trained and competent in the safe work procedures for concrete pouring and formwork installation. Training must include hazard awareness, PPE requirements, and emergency procedures.
7.2 Pre-Job Briefing
Pre-Job Briefing: A pre-job briefing must be conducted before starting any concrete pouring or formwork installation work. The briefing must cover the scope of work, potential hazards, control measures, and emergency procedures.
7.3 Work Area Preparation
Work Area Preparation: The work area must be properly prepared before starting work. This includes ensuring adequate lighting, ventilation, and access. Remove any obstructions and ensure the area is clean and free of slip and trip hazards.
8. Safe Work Procedure Steps
- Pre-Pour Inspection: Inspect the formwork for proper alignment, bracing, and support. Ensure all required materials and equipment are on hand. Verify that all workers are wearing the required PPE.
- Concrete Mixing: Follow the specified mix design. Add water gradually to achieve the desired consistency. Avoid creating excessive dust.
- Concrete Placement: Place concrete in layers, avoiding segregation. Use vibrators to consolidate the concrete and eliminate air pockets. Ensure concrete does not pile up in one location. [2]
- Formwork Monitoring: Continuously monitor the formwork during concrete placement for any signs of bulging, slipping, uplifting, or sagging. Stop the pour immediately if any issues are observed. [2]
- Finishing: Use appropriate finishing techniques to achieve the desired surface. Avoid creating excessive dust during dry finishing operations. If dried concrete is handled and dust is created, there could be a silica hazard. This can happen during cutting concrete without water to control the dust, cleaning outlines using an air hose, or dry sweeping. [1]
- Curing: Cure the concrete according to specifications. Keep the concrete moist to prevent cracking.
- Form Removal: Do not remove forms until the concrete has gained sufficient strength to support its own weight and any superimposed loads. Follow the plans and specifications for form removal. [6]
9. Precautions and Safety Measures
- Never allow workers to ride concrete buckets.
- Provide runways, ramps, or scaffolds for concrete placement in elevated areas. [6]
- Lockout/tagout concrete mixers or other equipment during maintenance or repair. [6]
- Ensure adequate site access and layout for safe delivery and movement of equipment and materials. [5]
- Do not place construction loads on a concrete structure unless a qualified person determines it can support the loads. [5]
10. Emergency Procedures
10.1 General Emergency Response
In the event of an emergency, immediately stop work and assess the situation. Evacuate the area if necessary. Provide first aid and call for medical assistance if required.
10.2 Specific Emergency Scenarios
- Chemical burn from wet concrete: Immediately flush the affected area with clean, cool water for at least 15 minutes. Seek medical attention.
- Fall from height: Do not move the injured worker unless there is an immediate danger. Call for medical assistance and provide first aid.
- Formwork collapse: Evacuate the area immediately. Account for all workers. Contact a structural engineer to assess the stability of the remaining structure.
11. Incident Reporting and Investigation
All incidents, near misses, and hazards must be reported to the supervisor immediately. The supervisor will then complete an incident report and submit it to the safety department.
The safety department will investigate all reported incidents to determine the root cause and implement corrective actions to prevent recurrence.
Approved by: [NAME AND POSITION]
Date: [APPROVAL DATE]
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References
Page links are approximateWAC 296-155-675 - Scope, application, and definitions applicable to this part
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Rules for the Administration of the Oregon Safe Employment Act (Construction, Division 3, OSHA Oregon)
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