I need a SWP for concrete pouring and forming
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Published by SALUSConcrete 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]
Safety powered by SALUS
Sources used for this answer
[1] WAC [redacted identifier] - Scope, application, and definitions applicable to this part
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Open source documentSource excerpt
WAC [redacted identifier] Scope, application, and definitions applicable to this part. (1) Scope and application. This part sets forth re- quirements to protect all construction employees from the hazards as- sociated with concrete and masonry construction operations performed in workplaces covered under chapter 296-155 WAC. (2) Definitions applicable to this part. Bull float. A tool used to spread out and smooth the concrete. 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, who has authori- zation to take prompt corrective action to eliminate them. Controlling contractor. A prime contractor, general contractor, construction manager, or any other legal entity that has the overall responsibility for the construction of the project, including plan- ning, quality, and completion. Dead load. A constant load, without load factors, due to the mass (weight) of members, the supported structure and permanent attachments or accessories. Falsework. Formwork to support concrete and placing operations for supported slabs of concrete structures, including all supporting members, hardware, and bracing. Formwork. The total system of support for freshly placed or par- tially cured concrete, including the mold or sheeting (form) that is in contact with the concrete as well as all supporting members includ- ing shores, reshores, hardware, braces, and related hardware. Guy. A line that steadies a high piece or structure by pulling against an off-center load. Jacking operation. The task of lifting a slab (or group of slabs) vertically from one location to another (e.g., from the casting loca- tion to a temporary (parked) location, or from a temporary location to another temporary location, or to its final location in the struc- ture), during the construction of a building/structure where the lift- slab process is being used. Lift slab. A metho…
[2] WAC [redacted identifier] - General provisions
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Open source documentSource excerpt
- WAC [redacted identifier] General provisions. (1) General. All equipment, material and construction techniques used in concrete construction and masonry work must meet the applicable requirements for design, con- struction, inspection, testing, maintenance and operations as prescri- bed in ANSI A10.9-1997, Concrete and Masonry Work Safety Requirements. (2) Construction loads. You must not place any construction loads on a concrete structure or portion of a concrete structure unless the employer determines, based on information received from a person who is qualified in structural design, that the structure or portion of the structure is capable of supporting the loads. (3) Vertical loads. Vertical loads consist of a dead load plus an allowance for live load. The weight of formwork together with the weight of freshly placed concrete is dead load. The live load consists of the weight of workers, equipment, runways and impact, and must be computed in pounds per square foot (psf) of horizontal projection. (4) Lateral loads. Braces and shores must be designed to resist all foreseeable lateral loads such as wind, cable tensions, inclined supports, impact of placement, and starting and stopping of equipment. The assumed value of load due to wind, impact of concrete, and equip- ment acting in any direction at each floor line must not be less than 100 pounds per lineal foot of floor edge or two percent of total dead load of the floor, whichever is greater. Wall forms must be designed for a minimum wind load of 10 psf, and bracing for wall forms should be designed for a lateral load of at least 100 pounds per lineal foot of wall, applied at the top. Walls of unusual height require special consideration. (5) Special loads. Formwork must be designed for all special con- ditions of construction likely to occur, such as unsymmetrical place- ment of concrete, impact of machine-delivered concrete, uplift, and concentrated loads. (6) You must check form supports and wedges dur…
[3] Rules for the Administration of the Oregon Safe Employment Act (Construction, Division 3, OSHA Oregon)
Page 763
Open source documentSource excerpt
# Concrete and Masonry Construction (cont.) Concrete and Masonry Construction Q Oregon Occupational Safety and Health Division Oregon Administrative Rules AO 1-2003 Division 3 ## 1926.700 Scope, Application, and Definitions Applicable to this Subpart (a) Scope and application. This subpart sets forth requirements to protect all construction employees from the hazards associated with concrete and masonry construction operations performed in workplaces covered under 29 CFR Part 1926. In addition to the requirements in Subpart Q, other relevant provisions in Parts 1910 and 1926 apply to concrete and masonry construction operations. (b) Definitions applicable to this subpart. In addition to the definitions set forth in 1926.32, the following definitions apply to this subpart. - Bull float means a tool used to spread out and smooth concrete. - Formwork means the total system of support for freshly placed or partially cured concrete, including the mold or sheeting (form) that is in contract with the concrete as well as all supporting members including shores, reshores, hardware, braces, and related hardware. - Lift slab means a method of concrete construction in which floor, and roof slabs are cast on or at ground level and, using jacks, lifted into position. Limited access zone means an area alongside a masonry wall, which is under construction, and which is clearly demarcated to limit access by employees. - Precast concrete means concrete members (such as walls, panels, slabs, columns, and beams) which have been formed, cast, and cured prior to final placement in a structure. - Reshoring means the construction operation in which shoring equipment (also called reshores or reshoring equipment) is placed, as the original forms and shores are removed, in order to support partially cured concrete and construction loads. - Shore means a supporting member that resists a compressive force imposed by a load. - Vertical slip forms means forms which are jack…
[4] FATALITY NARRATIVE: Ironworker Killed When Rebar Cage Collapses
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Open source documentSource excerpt
FACE/WA Fatality Assessment FATALITY NARRATIVE and Control Evaluation Ironworker Killed When Rebar Cage Collapses* Industry: Structural Steel and Precast Concrete Contractors Task: Installing rebar cage Occupation: Journey level ironworker Type of Incident: Struck by falling object Release Date: April 12, 2011 Incident Date: February 19, 2009 Case No.: 09WA01101 SHARP Report No.: 71-100-2011 On February 19, 2009, a 23-year-old journey level ironworker died when a rebar cage collapsed. The victim worked for a structural steel erection contractor. The contractor was hired to perform steel rebar assembly and installation on the site of a new commercial office building. The job site work crew was erecting a steel rebar cage weighing about 5,600 lbs as part of a column structure. It measured 20x56 inches and 30 feet tall. They had previously erected 11 similar cages. The rebar cage was braced using 2x4's nailed together and attached to the building floor. A tower crane placed the cage into position and then released the cage. The victim and another crew member were climbing the cage to make adjustments to the rebar and set the braces. Both workers had fall protection gear and were working on the same side of the cage when the crew noticed the cage began to lean. The crew attempted to reconnect the crane to the cage, but before they were able to one of the 2x4 braces failed and the cage collapsed. The victim was struck by the falling rebar cage and died of blunt force injury of the head at the scene. The other worker escaped without injury. ## Requirements ! Ensure that reinforcing steel for columns, walls, and similar vertical structures is guyed or supported to prevent collapse. See WAC [redacted identifier] ! Make sure your accident prevention program (APP) addresses hazards and abatement methods when installing reinforcing columns, walls, and similar vertical structures. See WAC [redacted identifier] ! Ensure that the inspection of rigging …
[5] Construction Safety and Health Standards (MIOSHA)
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Open source documentSource excerpt
# MINIMUM SAFETY FACTORS OF FORMWORK ACCESSORIES* (cont.) ## R 408.[redacted postal code] Concrete mixing, pouring, and floating. (cont.) loose material from accumulating on the top and sides of the bucket. (7) An employee shall not be permitted to ride bucket or walk or work under a bucket that is suspended from a crane or cableway. a (8) A concrete bucket that is positioned by a crane or cableway shall be suspended from an approved swivel safety-type hook. (9) A pumpcrete or similar system using discharge pipe shall have pipe supports that are designed for a 100% overload. Compression air hoses in the system shall be provided with positive fail-safe joint connectors to prevent the separation of sections when pressurized. (10) A runway, ramp, or scaffold shall be provided for placement of concrete in areas such as walls, piers, columns, and beams, as prescribed in Construction Safety Standards Part 12 "Scaffolds and Scaffold Platforms," Part 21 "Guarding of Walking and Working Areas," and Part 45 "Fall Protection," as referenced in R 408.[redacted postal code]. (11) A concrete mixer, or other equipment, such as a compressor, screen, or pumps used for concrete construction activities, where inadvertent operation of the equipment may occur and cause injury, shall be locked out when an employee is performing maintenance or repair. An employee who is inside a concrete mixer performing maintenance or repair shall have the only key to the lock. (12) Sections of tremies and similar concrete conveyances shall be secured with wire rope, or equivalent materials, in addition to the regular couplings or connections. ## R 408.[redacted postal code] Forms and shoring generally. - Rule 2521. (1) Formwork, shoring, and reshoring shall be designed, erected, supported, braced, and maintained so that they will support all vertical and lateral loads that may be imposed upon them during placement of concrete or until the loads can be supported by the concrete structure. (2)…
[6] Toolbox Talk: Concrete Placement
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Open source documentSource excerpt
# CONCRETE PLACEMENT Date Posted: 05/12/2025 ## Concrete Placement Concrete is composed of cement, sand, and aggregate, which are a collection of raw materials, like sand, gravel, and crushed stone, that make up a large portion of concrete and water. When these components are mixed in the correct proportions, concrete becomes a stable and versatile building material that can be used for various applications such as roads, bridges, buildings, septic tanks, and even household countertops. The versatility of concrete in building applications can be achieved by adjusting the proportions of air and other variables in the mixture. Additionally, strengthening materials like re-bar, fiberglass strands, and plastic rods are added to reinforce the concrete. According to the Center for Construction Research and Training (CPWR), there were over 3,000 injuries that resulted in days away from work due to concrete pour- related work. Concrete work is often physically demanding and poses many hazards for those working in this field. Although there may be a need for a steady or fast pace at times, it is crucial to take the time to identify the hazards of the work and minimize them. ## HAZARDS OF WORKING WITH CONCRETE - Chemical burns: It is crucial to protect your skin from coming into direct contact with concrete. Dry cement and wet concrete can lead to skin irritation, dermatitis, or even a chemical burn. The chemicals in cement extract moisture from anything to help in the drying process. When cement pulls the moisture from the skin, it damages the skin cells severely. If left untreated, once concrete hardens, the skin will blister, swell, and bleed, resulting in a second to third- degree burn. In the most severe cases, skin contact with concrete has led to scarring, the need for skin grafts, and even amputations. Therefore, it is essential to wear proper PPE such as gloves, boots, and eye protection when working with cement materials like wet concrete. It is frequently r…
[7] IHSA Safety Tool Box talks
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Open source documentSource excerpt
# Formwork-Placing concrete ## Explain dangers When it comes to placing concrete, the most important consideration is to ensure that formwork and falsework are complete. Some of the major hazards associated with placing concrete include - Overloading formwork and falsework, especially if concrete piles up in one location or is poured too fast - Working at dangerous heights near perimeters of decks, stairs, and shaft openings, or accessing platforms on wall and column forms - Electrocution and shock if power tools, extension cords, and other electrical equipment are used near wet concrete or other wet areas. Concrete buckets and concrete pumps can also make contact with overhead powerlines. - Overhead powerlines, being struck by equipment, and pinch points when receiving concrete pumps or buckets • Skin burns, severe allergic reactions, and dryness if skin is exposed to wet concrete, if clothing becomes soaked, or if concrete enters your boots • Slips and trips due to poor housekeeping - Cuts and impalement when rebar is not properly protected with caps. ## Identify controls - Have guardrails in place around perimeters, stairs and shafts, and work platforms on walls and column forms. . Ensure that formwork has been inspected by a professional engineer or by a competent worker designated by the professional engineer before the placement of concrete. - Make sure all rebar that is not part of the pour is properly capped to avoid cuts, abrasions, and impalement. - Before pouring, have extra shores and other materials readily available in case of an emergency. • Inspect forms before the pour to ensure they are free of debris. - Ensure the area around the pour is clean to avoid slips and trips. - Always follow the specified pour rate, techniques, and procedures. - Monitor the condition of forms before pouring and as concrete is placed. Bulging, slipping, uplifting, sagging, etc., are signs that the pour should be stopped immediately. - If …
[8] Toolbox Talk: Concrete and Masonry Safety
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Open source documentSource excerpt
# CONCRETE AND MASONRY SAFETY ## Date Posted: 05/29/2024 Concrete is a common building material used regularly in the construction industry. Concrete generally made by combining cement, sand, aggregate (small stones), and water. Some applications of concrete necessitate adding other materials that could adversely affect health if improperly handled or appropriate precautions are not taken. Additions may include alkaline compounds (such as lime) that are corrosive to human tissue. Crystalline silica can be abrasive to the skin and cause lung damage, and small quantities of chromium can cause allergic reactions. According to the Occupational Safety and Health Administration (OSHA), over 250,000 people work i concrete or masonry trades. Over 10 percent of those workers (28,000) experienced a job-related injury or illness, and 42 died in just a year. ## HAZARDS WORKING WITH CONCRETE • Eye, skin, and respiratory tract irritation from exposure to cement dust. • Inadequate safety guards on equipment. • Ergonomic risk (overexertion and awkward postures). - Slips, trips, and falls. • Chemical burns from wet or dry concrete. - Confined spaces • Noise exposure ## DIFFERENT PHASES OF WORKING WITH CONCRETE PRESENT DIFFERENT RISKS Forming risks: Concrete forming is the process of creating solid frames to hold the concrete in place as it sets after being poured. Most concrete projects require forms before you even order or mix the concrete. You need use structurally sound forms to hold the concrete in place and avoid collapse. Risks during this stage include: to • Workers falling during steel fixing (tying rebar) and the erection of formwork. • Collapse of the formwork. • Materials falling during the striking of formwork. • Silica dust exposure. • Manual handling of materials such as formwork, reinforcing bars (rebar), etc. • Skin irritation. Mixing risks: Cement dust released during bag dumping or concrete cutting can irritate the skin. Moisture from sweat …
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