Safe Work Method Statement

Concrete Placement and Finishing Safe Work Method Statement

Comprehensive Australian WHS Compliant SWMS

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Overview

What this SWMS covers

Concrete placement and finishing encompasses the critical construction processes of receiving ready-mixed concrete at site, placing concrete into prepared formwork or substrate locations, spreading and consolidating concrete to eliminate voids and achieve specified density, screeding concrete surfaces to design levels and grades, floating to close surface texture and embed aggregate, power troweling or hand troweling to achieve final finish specifications, and implementing appropriate curing regimes to develop concrete strength and durability. These operations are fundamental to virtually all construction projects from residential slabs and footings through to multi-storey commercial buildings, bridges, roads, and infrastructure works. Concrete placement and finishing operations occur across diverse construction applications with techniques adapted for specific structural elements and finish requirements. Ground-level slab placement typically involves large volumes of concrete delivered by multiple trucks over several hours, with laser-guided screeding equipment achieving precise level tolerances and power trowels producing smooth trafficable surfaces. Elevated slab placement in multi-storey construction uses concrete pumps or crane-lifted kibbles to transport concrete vertically, with placement occurring in sections coordinated with formwork capacity and curing schedules. Column and wall placement requires careful concrete flow control preventing segregation while ensuring complete formwork filling without voids, using vibration equipment to consolidate concrete around dense reinforcement steel. The work is performed by qualified concreters with trade certifications or extensive experience, working in crews typically comprising a leading hand coordinating placement sequencing, concreters operating screeds and finishing equipment, and laborers assisting with concrete spreading and material handling. Modern finishing equipment includes laser-guided screeding systems achieving 2mm level tolerance over 3-metre distances, ride-on power trowels for efficient finishing of large floor areas, and specialized tools for edge details and hard-to-reach locations. Environmental conditions significantly impact placement timing and techniques, with hot weather requiring early morning or evening placement schedules to avoid excessive concrete temperatures, cold weather requiring concrete heating or insulated curing blankets, and wet weather potentially requiring placement postponement to prevent concrete quality degradation.

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Why this SWMS matters

Reinforce licensing, insurance, and regulator expectations for Concrete Placement and Finishing Safe Work Method Statement crews before they mobilise.

Hazard identification

Surface the critical risks tied to this work scope and communicate them to every worker.

Risk register

Manual Handling Injuries from Concrete Spreading and Finishing

high

Concrete placement and finishing involves sustained heavy manual handling throughout multi-hour pours with workers using long-handled rakes, shovels, and screeds to spread wet concrete weighing approximately 2.4 tonnes per cubic metre. Each shovel load represents 15-20kg of material requiring lifting, carrying, and throwing movements performed hundreds of times during typical placement operations. Screeding work requires workers to pull or push screeding equipment across concrete surfaces while maintaining awkward bent or kneeling postures to achieve specified levels, with some residential slab pours requiring screeding distances of 50+ metres creating sustained exertion. Floating and troweling operations involve repetitive arm and shoulder movements with workers leaning over concrete surfaces applying pressure to finishing tools, with work continuing for hours as concrete reaches finishing condition across large slab areas. The sustained nature of concrete finishing creates cumulative fatigue without opportunity for recovery breaks, as stopping mid-pour would compromise concrete quality through cold joint formation. Workers typically cannot maintain neutral spine positions during concrete spreading and leveling, instead working in forward-bent postures that load lumbar spine structures and create disc compression. Concrete finishing demands kneeling on concrete surfaces for extended periods causing knee injuries and aggravating existing joint conditions, while the wet environment prevents use of knee pads that would become saturated and uncomfortable. Physical demands are compounded by time pressure to complete finishing before concrete initial set prevents working, creating incentive to work faster despite accumulating fatigue. Environmental factors including heat stress and dehydration during summer concrete pours reduce worker physical capacity while increasing exertion required for equivalent work output. The cumulative effect of repeated concrete pours over weeks and months causes chronic musculoskeletal injuries affecting backs, shoulders, knees, and wrists, with many experienced concreters developing permanent disabilities limiting their capacity for continued work in the trade.

Consequence: Chronic lower back pain and disc injuries requiring long-term medical treatment, shoulder rotator cuff injuries from repetitive overhead and pushing movements, knee cartilage damage and arthritis from prolonged kneeling, career-ending disabilities for concreters unable to perform heavy manual handling

Cement Burns and Dermatitis from Wet Concrete Contact

high

Portland cement in wet concrete is highly alkaline with pH typically 12-13, causing progressive chemical burns through prolonged skin contact that may not be immediately painful but result in severe tissue damage over hours. Concrete placement work creates continuous wet concrete exposure as workers handle concrete with rakes and shovels, kneel in wet concrete during finishing operations, and experience concrete splatter on arms and legs during spreading and consolidating. Traditional cotton work gloves absorb cement-laden water bringing alkaline solution into direct contact with skin and preventing evaporation that would limit exposure duration, effectively worsening cement exposure rather than preventing it. Waterproof gloves provide better protection but often fail or tear during concrete work exposing skin to direct concrete contact, with workers reluctant to replace gloves frequently due to cost and work interruption. Concrete frequently enters boots through top openings during ground-level work or through boot lace areas, with wet concrete trapped against skin on feet and lower legs for hours causing severe burns that often develop overnight after work completion when pain prevents sleep. The chemical burn process involves cement alkalinity breaking down skin oils and proteins causing progressive tissue destruction, with burns developing slowly over 2-4 hours of exposure rather than immediately making workers unaware of ongoing damage. Repeated cement exposure causes occupational dermatitis where skin becomes sensitized to cement creating allergic reaction with subsequent exposures, resulting in painful cracking, bleeding, and permanent skin damage. Workers who develop cement dermatitis may become unable to continue concreting work as any cement exposure triggers severe reaction, effectively ending their careers in the trade. The condition is particularly severe for workers with existing skin conditions or cuts providing direct cement access to subcutaneous tissue. Concrete splatter reaching face and eyes creates risk of chemical burns to facial skin and serious eye injury requiring immediate eyewash treatment to prevent permanent damage. Summer conditions with exposed skin due to heat create increased burn risk as more skin surface area is exposed to concrete contact, while perspiration creates moisture that enhances cement dissolution and skin absorption.

Consequence: Second and third-degree chemical burns requiring skin grafts and causing permanent scarring, chronic occupational dermatitis ending careers in concrete trades, eye injuries potentially causing vision loss, painful skin conditions requiring ongoing medical treatment and limiting work capacity

Slips, Trips and Falls on Wet Concrete Surfaces

medium

Wet concrete creates extremely slippery surfaces with coefficient of friction approaching zero on smooth troweled concrete, causing frequent slips particularly when workers wearing concrete-contaminated boots transition between wet concrete and surrounding surfaces. Concrete placement areas contain numerous trip hazards including formwork components, reinforcement steel projecting from completed sections, concrete delivery hoses and cords, finishing equipment, and construction materials stored at slab perimeters creating obstacles in pathways. The dynamic work environment during concrete placement has workers moving continuously around placement area in response to concrete flow from pumps or trucks, with attention focused on concrete spreading rather than foot placement and obstacle avoidance. Poor lighting during early morning or evening concrete pours common in summer heat avoidance scheduling creates reduced hazard visibility and increased slip and trip risk. Workers often walk backward while pulling screeds or raking concrete creating inability to see obstacles or changes in walking surface behind them. Wet concrete buildup on boot soles creates raised slippery platform eliminating boot tread effectiveness and causing balance instability, with workers sometimes deliberately stepping in wet concrete to clean boot soles creating fresh slip hazard. Falls onto wet concrete or reinforcement steel cause impact injuries including fractures, lacerations, and puncture wounds, with reinforcement penetration injuries creating severe trauma and infection risk. Falls at elevated slab locations or near slab edges create potential for falls to lower levels causing serious or fatal injuries, with edge protection sometimes temporarily removed or rendered ineffective to accommodate concrete placement access. The rapid pace of work and continuous concrete flow from delivery trucks or pumps discourages stopping to address housekeeping issues or clean walkways, allowing hazardous conditions to accumulate throughout placement operation. Workers attempting to catch themselves during slips often thrust arms into wet concrete or grab reinforcement steel causing cement burns or lacerations compounding the slip injury.

Consequence: Fractures from falls onto concrete or formwork, lacerations and puncture wounds from reinforcement steel, cement burns to hands thrust into concrete during slip recovery, potential fatal falls from elevated slabs when edge protection compromised during placement

Heat Stress During Sustained Concrete Placement Operations

high

Concrete placement operations frequently occur during hot weather periods with ambient temperatures exceeding 30-35°C common across most Australian regions in summer months, combined with high physical workload from manual handling creating metabolic heat that adds to environmental heat stress. The continuous nature of concrete placement prevents normal work-rest cycles as stopping mid-pour creates cold joints compromising structural integrity, resulting in sustained exertion for 4-8 hours during typical concrete pours with inadequate recovery breaks. Workers performing concrete finishing in direct sun exposure experience radiant heat loading significantly exceeding ambient air temperature, with concrete surface temperatures reaching 45-50°C adding to heat stress through conductive heat transfer during kneeling and contact work. Personal protective equipment including waterproof boots, gloves, long pants and long sleeve shirts to prevent cement burns restricts heat dissipation through evaporative cooling, creating additional heat stress burden. Dehydration develops rapidly during concrete work with fluid losses through perspiration often exceeding 2-3 litres per hour in extreme conditions, with workers focused on completing concrete placement neglecting fluid replacement until serious dehydration symptoms develop. Early heat stress symptoms including fatigue, headache, and reduced concentration are often attributed to work demands rather than recognized as heat illness, allowing progression to heat exhaustion with nausea, dizziness, and confusion. Heat stroke represents medical emergency with core body temperature exceeding 40°C causing organ damage and potentially fatal outcomes if not treated immediately, yet concrete crews may be working in remote site locations without immediate medical support access. Concrete curing generates additional exothermic heat from cement hydration reactions, with workers returning to apply curing compounds or install curing covers exposed to residual heat from both sun and curing concrete. The combination of heavy work, environmental heat, continuous exertion without breaks, and pressure to complete placement before concrete becomes unworkable creates perfect conditions for heat-related illness, with fatalities occurring in Australian construction most years from heat stroke during summer concrete operations. Older workers and those with pre-existing medical conditions including cardiovascular disease face higher heat stress risk but often occupy leading hand positions requiring sustained site presence throughout placement operations.

Consequence: Heat exhaustion causing severe nausea, disorientation and collapse requiring medical treatment, heat stroke causing permanent organ damage or fatality, dehydration-related kidney damage from sustained fluid loss, cardiovascular events triggered by heat stress in susceptible individuals

Noise Exposure from Concrete Vibrators and Power Trowels

medium

Concrete consolidation using petrol or electric vibrators generates noise levels typically 95-105 dB(A) measured at operator position, well above the 85 dB(A) threshold requiring hearing protection under Australian WHS regulations. Power trowels used for concrete finishing produce noise levels of 90-100 dB(A) depending on engine size and operating condition, with ride-on power trowels producing sustained high noise throughout finishing operations lasting 2-4 hours for typical floor slabs. Concrete pump operations create noise from diesel engines and concrete flow through pump lines adding to overall noise environment, while concrete truck mixers rotating during concrete discharge contribute additional noise. The cumulative noise exposure during concrete placement operations often exceeds daily noise dose limits even during single concrete pour, with workers exposed to multiple noise sources simultaneously rather than individual tools. Communication difficulties in high-noise environment create safety risks when workers cannot hear warnings, crane signals, or traffic movements, leading to verbal communication being replaced by unreliable gesturing. Many concreters work without adequate hearing protection despite obvious noise hazards, with earplugs uncomfortable during extended wear and earmuffs incompatible with hard hat use or causing heat stress through reduced head cooling. The sustained nature of finishing operations prevents workers from removing themselves from noise hazard during rest breaks, as concrete finishing condition progresses continuously requiring operator presence at machinery. Younger workers often underestimate hearing damage risk as noise-induced hearing loss accumulates gradually over years without obvious immediate symptoms, leading to inadequate hearing protection use early in careers when prevention would be most effective. The irreversible nature of noise-induced hearing loss creates permanent disability affecting not only work capacity but also quality of life through social isolation and communication difficulties. Tinnitus causing constant ringing sensation develops in many workers exposed to high noise levels, creating additional stress and sleep disruption beyond measured hearing loss.

Consequence: Permanent noise-induced hearing loss reducing hearing capacity across speech frequencies, tinnitus causing constant ear ringing and sleep disruption, communication difficulties affecting both work and social situations, reduced hazard awareness from inability to hear warning sounds or alarms

Formwork Overload and Collapse During Concrete Placement

high

Formwork systems must support the full weight of wet concrete during placement plus dynamic loads from concrete flow, worker traffic, and equipment operation, with inadequate formwork design or construction causing catastrophic collapse striking multiple workers simultaneously. Concrete flow into formwork creates lateral pressures against wall and column formwork increasing with concrete head height and placement rate, with rapid placement creating pressure surges exceeding static design pressure by 30-50%. Formwork failures typically occur during peak loading periods when concrete placement is most active and multiple workers are present in the collapse zone, causing high potential for multiple serious injuries or fatalities from single incident. Contributing factors to formwork collapse include inadequate props or shores supporting inadequate load capacity, improper bracing or ties allowing formwork lateral movement, formwork components damaged during previous use and not adequately repaired or replaced, ground conditions beneath formwork shores settling under load, and exceeding design pour rates specified in formwork engineering. Elevated slab formwork collapse drops workers positioned on formwork and creates falling debris hazard for workers below, while wall formwork collapse can bury workers under formwork components and wet concrete. The progressive nature of some formwork failures allows partial collapse or movement detected before total failure, providing warning opportunity if workers recognize signs and evacuate immediately, but time pressure during concrete placement may lead workers to continue operations despite formwork distress indications. Visual inspection during concrete placement rarely detects formwork overstress until movement is obvious, requiring pre-placement engineering review and periodic observation by competent person during placement to identify potential problems. Concrete vibration during consolidation adds dynamic loading to formwork that can trigger failure of marginally adequate formwork systems, particularly when multiple vibrators operate simultaneously creating resonant vibration patterns. Recovery from formwork failure often requires stopping concrete placement leaving truck loads of concrete unplaced, creating additional pressure to continue placement despite formwork concerns.

Consequence: Multiple fatalities from formwork collapse crushing workers, serious injuries including fractures and crush syndrome requiring extended hospitalization, structural damage requiring demolition and rebuilding of incomplete elements, project delays and costs from incident investigation and remedial work

Control measures

Deploy layered controls aligned to the hierarchy of hazard management.

Implementation guide

Mechanical Concrete Handling Equipment to Eliminate Manual Lifting

Elimination

Mechanical handling equipment eliminates or substantially reduces manual handling of concrete by workers, addressing the primary injury risk in concrete placement operations. Concrete pump systems including boom pumps and line pumps deliver concrete directly to placement location minimizing manual handling to spreading and finishing work only, eliminating repeated lifting and carrying of concrete in wheelbarrows or buggies. Laser-guided screed systems including automated and semi-automated screeding machines level concrete to specified grades using laser receivers controlling screed elevation, reducing manual screed pulling force by 70-80% compared to traditional screeding. Ride-on power trowels allow operators to finish large slab areas from seated position eliminating bent postures and sustained kneeling work, with modern machines incorporating ergonomic seating and controls reducing operator fatigue. Concrete buggies with powered assistance or motorized concrete buggies transport concrete short distances from delivery point to placement location without manual wheelbarrow pushing, particularly effective for ground-level work where pump access is limited. Walk-behind power floats and trowels reduce hand-arm strain from hand finishing tools while accelerating finishing work, allowing appropriate finishing timing without compressed schedules forcing rushed manual work. The elimination hierarchy represents the most effective control measure as hazards are removed rather than controlled, with investment in mechanical equipment providing long-term injury reduction benefits. Equipment selection must match job requirements with boom pump capacity and reach adequate for building height and placement distances, and finishing equipment size appropriate for slab areas and access constraints. Operator training for mechanical equipment ensures safe and effective use maximizing manual handling reduction benefits while preventing equipment-related incidents. Maintenance of mechanical equipment is essential to ensure reliability during time-critical concrete placement when equipment breakdown would force reversion to manual handling methods.

Implementation

1. Specify concrete pump requirement in project planning for all concrete pours exceeding 10 cubic metres or where placement locations are more than 20 metres from truck access points 2. Select boom pump capacity based on building height and maximum reach requirements, ensuring pump can access all planned pour locations without relocating 3. Invest in laser-guided screed systems for slabs exceeding 100 square metres, selecting automated systems for large commercial projects and semi-automated for residential work 4. Provide ride-on power trowels for all slabs exceeding 200 square metres, with walk-behind power floats for smaller areas or constrained access locations 5. Maintain concrete buggy fleet including minimum two motorized buggies for each ground-level pour crew reducing manual wheelbarrow use 6. Schedule equipment maintenance during non-pour periods ensuring all mechanical handling equipment is fully operational before concrete delivery 7. Train all concrete crew in operation of mechanical equipment including troubleshooting common issues preventing work stoppages during pours 8. Develop equipment breakdown contingency plans identifying backup equipment sources or alternative placement methods if primary equipment fails 9. Calculate mechanical handling equipment costs into project budgets ensuring equipment investment is valued appropriately against manual handling injury costs 10. Monitor manual handling injury rates tracking effectiveness of mechanical equipment implementation and identifying remaining manual handling improvement opportunities

Comprehensive Skin Protection Program for Cement Exposure Prevention

PPE

Systematic skin protection prevents cement contact during all phases of concrete work, addressing chemical burn and dermatitis hazards through multiple protective layers. Waterproof gloves specifically designed for cement work use nitrile or PVC coating extending minimum 300mm up forearms providing effective barrier against wet concrete, with gloves replaced immediately upon any coating damage exposing skin. Long-sleeve cotton shirts under waterproof coveralls or bib overalls prevent concrete splatter contact with arms and torso, with waterproof garments shedding concrete rather than absorbing moisture like cotton alone. Waterproof trousers or reinforced work pants prevent cement-contaminated water from reaching leg skin, with particular attention to preventing concrete entering boot tops through proper overlap of trousers over boots. Rubber boots with sealed construction prevent cement water penetration while providing slip resistance on wet concrete, with boot height minimum 300mm preventing concrete entry during ground-level work. Barrier creams applied to exposed skin before work provide additional chemical resistance creating sacrificial layer that is removed during washing taking absorbed cement with it, though barrier creams supplement rather than replace gloves and protective clothing. Immediate washing facilities accessible at all concrete work areas allow workers to remove cement contact within minutes preventing burn development, with eye wash stations mandatory for face and eye splash events. The skin protection program requires worker education about cement burn mechanisms explaining that pain is not immediate warning of damage, emphasizing prevention through consistent PPE use rather than relying on discomfort to indicate harmful exposure. Regular skin monitoring by workers and supervisors identifies early dermatitis symptoms allowing prompt treatment before severe skin damage develops, with workers exhibiting skin reactions removed from cement contact until condition resolves. PPE replacement schedules ensure adequate stocks of gloves and protective clothing are always available with damaged items replaced immediately rather than workers continuing to use inadequate protection.

Implementation

1. Provide each concrete worker with minimum three pairs of waterproof nitrile-coated gloves per shift, with gloves replaced immediately if coating damaged 2. Supply long-sleeve cotton shirts and waterproof bib overalls or coveralls to all workers handling wet concrete, with garments laundered after each use 3. Issue rubber boots with minimum 300mm height and sealed construction to prevent cement water entry, replacing boots annually or when waterproofing compromised 4. Establish washing facilities maximum 30 metres from concrete work areas, including soap, towels, and running water for immediate cement removal 5. Install eyewash station at concrete placement area with 15-minute water supply capacity meeting AS 4775 requirements for emergency eye irrigation 6. Train workers in skin protection requirements during site induction and before each concrete pour, emphasizing consistent PPE use throughout placement operations 7. Implement glove inspection protocol requiring workers to check gloves for coating damage before each use and during breaks in concrete placement 8. Provide barrier cream (pre-work skin protection cream) to all concrete workers with application required before starting work and reapplied after breaks or washing 9. Conduct weekly skin inspections by supervisor checking hands and forearms of all concrete workers for early dermatitis signs including redness, dryness, or cracking 10. Document cement exposure incidents including burns and dermatitis cases, investigating to identify PPE failures or procedural gaps requiring corrective action

Heat Stress Prevention and Management Program

Administrative

Systematic heat stress prevention protects workers during concrete placement in hot weather through environmental monitoring, work scheduling, hydration management, and physiological monitoring. Weather forecasting integrated into concrete pour planning reviews predicted temperatures and humidity for scheduled pour dates, with pours rescheduled to cooler times or days when extreme heat is forecast. Early morning concrete placement scheduling commences work at 5-6am completing concrete finishing before peak daily temperatures, accepting night work penalties as acceptable cost to prevent heat illness. Structured work-rest cycles during hot weather concrete work mandate rest breaks in shaded areas with duration and frequency based on environmental heat index, overriding production pressures that would otherwise prevent breaks. Shaded rest areas with cooling facilities including fans, misting systems, or air conditioning provide effective heat recovery allowing core body temperature reduction during breaks, located immediately adjacent to work areas minimizing transition time. Hydration management provides cool drinking water in insulated containers positioned at multiple locations around concrete placement area with individual bottles for each worker eliminating disease transmission concerns, with minimum 1 litre per worker per hour consumption target enforced through active encouragement. Electrolyte replacement drinks supplement water providing salt replacement for profuse sweating, though water remains primary hydration fluid. Worker heat stress monitoring uses buddy system with workers observing each other for heat illness symptoms including confusion, excessive fatigue, cessation of sweating, and altered behavior, with authority for any worker to call work stoppage if concerned about another worker's condition. Acclimatization protocols for new workers or workers returning from leave gradually increase work duration over 7-14 days allowing physiological adaptation to heat stress, preventing heat illness that commonly affects non-acclimatized workers during initial hot weather exposure. The administrative control requires supervisor commitment to enforce heat stress prevention measures overriding production pressure, with clear authority for health and safety representatives or workers to stop work if heat stress controls are inadequate.

Implementation

1. Review Bureau of Meteorology forecasts for scheduled concrete pour dates minimum 48 hours in advance, rescheduling pours if temperatures exceeding 35°C predicted 2. Schedule concrete pours for 5-6am start time during summer months when daytime temperatures exceed 30°C, coordinating early start with concrete supplier and pump operator 3. Establish work-rest cycle of 45 minutes work followed by 15 minute rest when temperature exceeds 30°C, reducing to 30 minutes work and 30 minutes rest above 35°C 4. Install shade structures using pop-up gazebos or temporary shade cloth creating minimum 12 square metres shaded rest area for each 6-person concrete crew 5. Position insulated water coolers at minimum three locations around concrete placement area, filled with ice water before work commencement and refilled as needed 6. Provide individual marked water bottles (1 litre capacity minimum) to each worker requiring visible consumption of one bottle minimum per hour 7. Supply electrolyte drinks (sports drinks) in addition to water, providing one 600ml electrolyte drink per two hours work for each worker 8. Implement buddy system pairing workers to mutually monitor for heat stress symptoms, with specific training in recognizing heat exhaustion and heat stroke signs 9. Require supervisor to conduct formal heat stress check every 30 minutes during hot weather concrete work, directly asking each worker about symptoms and observing for signs 10. Develop heat illness response procedures including immediate work cessation, moving affected worker to shade, active cooling with wet towels and fans, emergency services notification if heat stroke suspected, and incident investigation before work resumption

Pre-Placement Formwork Inspection and Sign-Off System

Administrative

Systematic formwork inspection before concrete placement verifies formwork adequacy preventing collapse incidents through documented engineering review and inspection sign-off requirements. Engineered formwork designs prepared by structural engineer or formwork engineer specify formwork components, propping requirements, maximum concrete pour rates, and maximum concrete head pressures, with designs stamped by engineer accepting design responsibility. Pre-placement inspection checklist covers formwork component condition checking for damage from previous use or storage, correct installation of formwork shores and props per engineered design, adequate bracing preventing lateral movement during concrete placement, secure formwork ties preventing formwork spreading under concrete pressure, appropriate release agent application allowing formwork stripping without damage, clear identification of areas ready for concrete placement, and documentation of inspection findings with defects rectified before placement approval. Inspection must be conducted by competent person with formwork knowledge and experience, typically qualified carpenter or formwork supervisor, independent of crew who installed formwork providing objective assessment. Visual indicators including paint markings or tags identify inspected and approved formwork sections distinguishing them from incomplete areas not ready for concrete placement, preventing concrete placement in uninspected locations. Hold points in concrete placement sequencing require inspector sign-off before concrete delivery commences, with concrete trucks not called to site until formwork inspection is complete and approval documented. The inspection system creates accountability with inspector identity recorded and formwork approval documented in site records providing evidence of due diligence if subsequent issues arise. Periodic observation during concrete placement monitors formwork performance with competent person watching for any movement or distress signs indicating inadequate formwork capacity, with authority to stop concrete placement if formwork issues develop. Post-placement monitoring continues during initial curing period when concrete loads are highest before strength development, checking that formwork remains stable without settlement or movement.

Implementation

1. Require engineered formwork design for all structural concrete elements including slabs, beams, columns and walls, with design stamped by structural engineer or specialist formwork engineer 2. Develop formwork inspection checklist based on engineered design covering all safety-critical components and installation requirements specific to project 3. Assign qualified person as formwork inspector, requiring minimum Carpentry trade qualification plus formwork experience, or Certificate IV in Building and Construction with formwork specialization 4. Conduct formwork inspection minimum 24 hours before scheduled concrete placement allowing time to rectify defects without delaying concrete delivery 5. Use spray paint or tags to mark inspected formwork sections indicating inspection complete and approval status, with different color for approved versus defects requiring rectification 6. Document formwork inspection findings in site diary or dedicated formwork inspection register, recording inspector name, date, areas inspected, defects found, and rectification requirements 7. Implement hold point preventing concrete truck dispatch until formwork inspection complete and approval documented, with site supervisor verifying approval before authorizing concrete delivery 8. Brief concrete placement crew on formwork inspection findings before pour commences, identifying any areas requiring special attention or pour rate limitations 9. Assign competent person to monitor formwork during concrete placement, watching for any movement, unusual sounds, or distress signs indicating potential formwork problems 10. Establish formwork emergency response procedures including immediate placement cessation, personnel evacuation from areas beneath elevated formwork, and engineer assessment before placement resumption if formwork issues detected

Hearing Protection Program with Noise Monitoring

PPE

Systematic hearing protection prevents noise-induced hearing loss through combination of noise exposure monitoring, appropriate hearing protection selection and use, and health surveillance identifying early hearing changes. Noise monitoring using calibrated sound level meters measures actual worker exposure during concrete placement operations including concrete vibrator use, power trowel operation, and pump noise, establishing noise exposure levels for different work tasks and equipment. Hearing protection selection provides protection adequate for measured noise levels with Class 4 or 5 earplugs providing 20-30 dB attenuation for high noise tasks, and Class 3 providing 15-20 dB attenuation for moderate noise environments, ensuring overprotection is avoided as excessive attenuation creates communication difficulties and isolation feelings encouraging removal. Multiple hearing protection options accommodate individual preferences with disposable foam earplugs, reusable corded earplugs, and earmuffs all provided allowing workers to select most comfortable option, though earmuffs may be impractical during hot weather work due to heat stress concerns. Communication while using hearing protection presents challenge addressed through electronic communication systems, hand signals supplementing verbal communication, and work procedures reducing need for continuous verbal interaction. The hearing protection program requires consistent enforcement as occasional hearing protection use provides minimal benefit with hearing damage occurring during unprotected noise exposure periods, requiring supervisors to actively monitor and enforce 100% hearing protection use in designated noise hazard areas. Training in hearing protection use covers correct insertion technique for earplugs achieving effective seal in ear canal, adjustment of earmuffs achieving consistent seal around ear, and hygiene practices including hand washing before handling earplugs preventing ear infections. Audiometric testing providing baseline hearing assessment followed by periodic retesting (typically annual or biennial) detects early hearing changes allowing work practice modification or enhanced hearing protection before significant permanent hearing loss develops, with testing conducted by occupational health service meeting AS/NZS 1269 requirements.

Implementation

1. Conduct noise monitoring during typical concrete placement operations measuring exposure at concreter, vibrator operator, and power trowel operator positions 2. Document noise exposure levels for each work task establishing noise zones requiring mandatory hearing protection (typically areas exceeding 85 dB(A)) 3. Provide multiple hearing protection options to all concrete workers including Class 4-5 disposable foam earplugs, Class 4-5 reusable corded earplugs, and Class 4-5 earmuffs 4. Install hearing protection stations at entry points to concrete work areas containing stocks of disposable earplugs and signs indicating hearing protection mandatory beyond this point 5. Train all workers in correct hearing protection use during site induction, demonstrating proper earplug insertion technique and verification of adequate seal 6. Designate high noise areas requiring hearing protection using signage meeting AS 1319 requirements including hearing protection symbol and decibel level indication 7. Implement supervisor monitoring of hearing protection compliance with authority to remove workers from site who refuse to use required hearing protection 8. Arrange baseline audiometric testing for all workers before commencing regular concrete work, establishing individual hearing baseline for comparison with subsequent tests 9. Schedule annual audiometric testing for workers regularly exposed to noise exceeding 85 dB(A), reviewing results for significant threshold shift indicating early hearing damage 10. Investigate any cases of hearing threshold shift identified in audiometric testing, reviewing work practices and hearing protection adequacy to prevent further deterioration

Download complete control procedures

Personal protective equipment

Waterproof Nitrile-Coated Gloves Extended Cuff

Requirement: Nitrile or PVC coated gloves minimum 300mm length with full hand and forearm coverage, resistant to alkaline cement exposure

When: Mandatory during all concrete handling, spreading, finishing and cleanup activities involving contact with wet concrete. Must be replaced immediately if coating damage exposes skin to cement. Cotton gloves are inadequate and increase cement exposure risk by absorbing cement water. Glove lifespan typically 4-8 hours during continuous concrete work requiring multiple pairs per shift.

Waterproof Rubber Boots with Steel Toe Cap

Requirement: Sealed rubber boots AS/NZS 2210.3 compliant with steel toe caps, minimum 300mm height, slip-resistant soles

When: Required for all concrete placement work preventing cement water penetration into boots that causes severe chemical burns to feet and lower legs. Boots must be high enough to prevent concrete entry over boot tops during ground-level work. Slip-resistant tread essential on wet concrete surfaces. Boots inspected daily for cracks or separation allowing cement water penetration.

Long-Sleeve Shirt and Waterproof Bib Overalls

Requirement: Cotton long-sleeve work shirt plus waterproof PVC or coated fabric bib overalls or coveralls covering torso and arms

When: Worn during all wet concrete work preventing cement splatter contact with skin on arms, chest, and legs. Cotton shirt absorbs perspiration while waterproof outer layer sheds concrete. Garments must be laundered after each use removing cement contamination. Damaged waterproof coating renders garments ineffective requiring replacement.

Class E Hard Hat

Requirement: AS/NZS 1801 Type 1 Class E hard hat with 4-point suspension providing electrical insulation and impact protection

When: Mandatory in all construction areas including during concrete placement for protection from falling tools, concrete splatter from pumps, and contact with overhead structure or services. Required when concrete pumps or elevated work platforms are operating overhead. Chin strap recommended during work at height or in windy conditions.

Hearing Protection Class 4-5

Requirement: Disposable foam earplugs or reusable earplugs providing minimum 20 dB noise reduction (Class 4-5 per AS/NZS 1270), or earmuffs providing equivalent attenuation

When: Required when operating or working within 5 metres of concrete vibrators, power trowels, concrete pumps, or other equipment generating noise exceeding 85 dB(A). Must be worn throughout duration of equipment operation. Earplugs must be inserted correctly achieving seal in ear canal per manufacturer instructions.

Safety Glasses with Side Shields

Requirement: AS/NZS 1337.1 safety glasses medium impact rated minimum, with side shields and anti-fog coating

When: Required during concrete placement protecting against cement splatter particularly during concrete pump discharge, concrete spreading, and vibrator use. Prescription safety glasses must meet same impact resistance standards. Safety glasses worn under face shields when grinding or cutting concrete during preparation work.

High Visibility Clothing Class D

Requirement: AS/NZS 4602.1 Class D daytime high visibility vest or shirt with fluorescent background and reflective tape

When: Mandatory when working in areas with mobile plant traffic including concrete trucks, pump trucks, and site vehicles. Particularly important during early morning or evening concrete pours in reduced light conditions. Garments must be clean with reflective properties intact, replacing faded or damaged items.

Sun Protection Including Hat and Sunscreen

Requirement: Broad-brimmed hat or cap with neck flap providing shade to face, ears and neck, plus SPF 50+ broad spectrum sunscreen reapplied every 2 hours

When: Required for all outdoor concrete work particularly during summer months when concrete pours often occur during peak UV hours. Hard hats with brim or attachable sun shields acceptable alternatives to separate hats. Sunscreen applied to all exposed skin including face, neck, ears, and backs of hands. AS/NZS 4399 compliant sun protective clothing recommended for sustained outdoor work.

Inspections & checks

Before work starts

✓Verify formwork inspection complete and documented with approval sign-off for concrete placement in designated areas
✓Check concrete delivery schedule confirms correct mix design, required quantity, delivery timing, and truck access route
✓Inspect all concrete placement equipment including pump hoses, vibrators, screeds, floats, and power trowels confirming operational status
✓Verify weather forecast for placement period with contingency plans developed for predicted rain, extreme heat, or high winds
✓Confirm water supply adequate for equipment cleaning, tool washing, and curing water application with hoses and fittings in place
✓Check PPE stocks adequate for concrete crew including sufficient waterproof gloves, rubber boots, and replacement items available
✓Verify washing facilities operational with soap and towels available, and eyewash station filled and accessible
✓Inspect reinforcement steel placement and tie-wire work complete per structural drawings with cover maintained to formwork
✓Confirm edge protection adequate at elevated slab locations with access gates for concrete placement identified
✓Conduct toolbox meeting reviewing concrete placement sequence, safety procedures, emergency response, and individual responsibilities

During work

✓Monitor workers using waterproof gloves throughout concrete handling with damaged gloves replaced immediately
✓Check formwork for any movement, unusual sounds, or visual distress during concrete placement indicating potential overload
✓Verify concrete temperature and slump at regular intervals (typically every truck or every 50 cubic metres) recording results
✓Observe workers for heat stress symptoms particularly during hot weather pours, enforcing scheduled rest breaks and hydration
✓Ensure hearing protection worn consistently during vibrator and power trowel operation, not just intermittently
✓Monitor concrete surface for proper consolidation and absence of segregation, adjusting placement rate or vibration if needed
✓Check that concrete placement proceeds per planned sequence avoiding excessive formwork loading in concentrated areas
✓Verify workers maintaining safe positions during concrete discharge from pumps or trucks, standing clear of hose whip zones
✓Observe housekeeping around concrete placement area ensuring walkways clear of trip hazards and excess concrete removed
✓Monitor time from concrete batching to placement ensuring concrete workability maintained within specification limits

After work

✓Clean all concrete equipment immediately after placement before concrete hardens, collecting wash water for proper disposal
✓Remove concrete contamination from PPE including gloves, boots, and clothing, discarding items too contaminated for effective cleaning
✓Inspect workers' hands and forearms for cement burns or early dermatitis signs, providing first aid treatment for any skin issues
✓Verify curing regime initiated per specification including application of curing compound, installation of wet hessian, or plastic sheeting
✓Check formwork remains secure during initial curing period with props and bracing intact, monitoring for any settlement or movement
✓Document concrete placement completion including volumes placed, areas completed, test results obtained, and any issues encountered
✓Conduct crew debrief identifying any safety issues, near misses, or procedure improvements for future concrete pours
✓Verify waste concrete disposed appropriately and work area cleaned preparing for subsequent construction activities

Step-by-step work procedure

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Pre-Placement Preparation and Equipment Setup

Begin concrete placement preparation minimum 2-4 hours before scheduled concrete delivery ensuring all preparatory work is complete before time-critical concrete work commences. Conduct formwork final inspection verifying forms are clean, release agent applied, joints sealed preventing grout loss, and formwork shores and bracing properly installed per engineering design. Check reinforcement steel placement confirms bar sizes, spacing, and positions match structural drawings with adequate concrete cover maintained to all formwork faces using plastic or concrete cover spacers. Verify formwork inspection sign-off documentation is complete with inspector approval recorded before concrete delivery is authorized. Assemble concrete placement equipment positioning pump lines or kibble landing areas at optimal locations for concrete distribution, setting up screeding equipment with laser receivers configured to design levels, and preparing finishing tools including floats, trowels, and edging tools. Test all mechanical equipment including power trowels, vibrators, and pump systems confirming operational status before concrete arrival prevents equipment failures during time-critical placement. Position material handling equipment including concrete buggies, wheelbarrows if needed, and shovels at strategic locations around placement area. Establish washing facilities at placement area perimeter including hoses with running water, soap dispensers, towels, and eyewash station tested for adequate water flow. Set up heat stress prevention facilities for hot weather pours including shade structures erected, water coolers filled with ice water, and rest areas designated away from active concrete work. Confirm PPE availability for all workers with adequate stocks of waterproof gloves, rubber boots in multiple sizes, and hearing protection at site. Review weather forecast for placement period checking for predicted rain, high winds, or temperature extremes requiring contingency planning or pour rescheduling. Conduct pre-start briefing for concrete crew reviewing placement sequence, concrete mix design and expected workability, safety procedures including skin protection requirements and heat stress prevention, individual responsibilities for placement coordination, and emergency procedures for formwork issues or worker injury. Coordinate final timing with concrete supplier confirming truck dispatch timing matched to crew readiness and traffic conditions allowing trucks to arrive at optimal intervals.

Safety considerations

Verify formwork design is adequate for planned concrete placement rate and maximum concrete head pressure to prevent formwork collapse. Ensure all workers understand skin protection requirements and consistently use waterproof gloves and protective clothing from start of concrete work. Confirm emergency response procedures including first aid access, eyewash station location, and emergency contact numbers. Check that adequate supervision is present throughout concrete placement operation.

Receive First Concrete Truck and Verify Mix Specification

Coordinate concrete truck arrival with site access personnel ensuring truck can enter site safely and maneuver to discharge location without obstruction. Receive concrete delivery docket from truck driver checking mix design specification matches project requirements including concrete grade (strength class), maximum aggregate size, slump specification, and any special requirements such as retarders for extended workability or accelerators for rapid strength gain. Verify concrete volume on docket matches ordered quantity ensuring adequate concrete for planned placement area without substantial excess or shortage. Check concrete batch time on docket confirming elapsed time from batching to delivery is within acceptable limits (typically 90 minutes maximum) for concrete workability maintenance. Conduct slump test on first truck concrete using slump cone per AS 1012.3 methodology, measuring slump to verify it is within specification tolerance (typically ±20mm of target slump). Record slump test result, concrete temperature, and test time documenting quality control testing for project records. If slump is outside specification or concrete appears overly stiff or fluid, reject load and contact concrete supplier for mix adjustment before placing non-conforming concrete. Perform air content test if concrete is air-entrained specification, using pressure method or volumetric method per AS 1012.4, verifying air content is within required range. Cast concrete test cylinders per AS 1012.8 using standard cylinder molds (100mm diameter × 200mm height), preparing minimum 6 cylinders from first truck and additional cylinders from subsequent trucks at required frequency (typically every 40-50 cubic metres). Label cylinders with project identification, placement date, truck number, and test age, preparing samples for testing at 7 days and 28 days to verify strength compliance. Position truck for concrete discharge ensuring truck stability on level ground with wheels chocked, confirming discharge chute or pump line connection points are properly positioned over formwork or designated placement area. Verify concrete placement crew is ready with equipment operational, PPE worn, and personnel in designated positions before authorizing truck driver to commence concrete discharge.

Safety considerations

Maintain safe clearance between concrete truck and workers during truck positioning, using spotter if driver visibility is limited. Ensure truck handbrake applied and wheels chocked before discharge commences. Verify workers have waterproof gloves on before any concrete contact during testing or placement. Position test cylinder preparation area away from active traffic and concrete flow.

Place and Spread Concrete into Formwork

Direct concrete discharge from truck or pump into formwork at controlled rate preventing formwork overload, segregation from excessive drop height, or uneven loading creating localized formwork stress. For slab placement, discharge concrete in multiple locations across slab area rather than concentrated in one location, moving discharge point progressively across slab as placement advances. Maintain discharge drop height below 1.5 metres preventing concrete segregation with coarse aggregate separating from mortar, using elephant trunk extensions or pump line positioning to limit fall distance. Spread concrete using rakes and shovels distributing concrete relatively evenly across formwork before detailed leveling, working concrete into corners and against formwork faces eliminating voids. For column and wall placement, place concrete in horizontal lifts maximum 600mm depth allowing consolidation of each lift before placing subsequent lift, preventing excessive lateral pressure on formwork from rapid filling. Direct concrete flow toward reinforcement steel ensuring concrete completely encases steel with no voids or honeycombing, working concrete between closely spaced bars using shovel or vibrator probe. Monitor formwork during concrete placement watching for any movement, bulging, or unusual sounds indicating formwork distress, immediately ceasing placement if formwork issues are detected. Control concrete placement rate to remain within formwork design limits (typically specified in cubic metres per hour per linear metre of wall), coordinating with truck driver or pump operator to adjust concrete flow rate if excessive. Prevent concrete spillage outside formwork by maintaining proper discharge control and having crew ready to catch any concrete overflow with shovels or buckets. For elevated slab placement, ensure adequate fall protection is maintained with workers using full body harnesses when working within 2 metres of unprotected edges, or temporary edge barriers remain in place with access gates used for concrete discharge points. Rotate workers between heavy manual handling tasks and lighter duties managing fatigue during sustained placement operations, implementing scheduled breaks for drink and rest even during continuous concrete flow.

Safety considerations

Maintain safe distance from concrete pump discharge points due to hose whip hazard if hose ruptures or coupling fails. Ensure workers do not stand on reinforcement steel or formwork edges while spreading concrete as slip could cause fall onto steel. Monitor workers for cement contact on exposed skin, requiring immediate washing if concrete splashes on arms or legs. Enforce hearing protection use when vibrators operating nearby.

Consolidate Concrete Using Vibration Equipment

Consolidate freshly placed concrete using internal vibrators (poker vibrators) to eliminate air voids, ensure complete formwork filling, and achieve proper concrete density for strength development. Insert vibrator probe vertically into concrete at regular intervals typically 400-600mm spacing, penetrating full depth of freshly placed concrete and extending 100-150mm into previously placed concrete layer creating monolithic connection between lifts. Hold vibrator in position 5-15 seconds observing for surface leveling, air bubble cessation, and appearance of mortar sheen at surface indicating adequate consolidation. Withdraw vibrator slowly at approximately same rate as insertion (50-100mm per second) preventing void formation behind probe as it is removed. Avoid over-vibration which causes segregation with coarse aggregate sinking and excess mortar rising, recognizing adequate consolidation by surface appearance and ceasing vibration when proper consolidation achieved. Do not use vibrator to move concrete horizontally across formwork as this causes segregation, instead placing concrete close to final position and vibrating only for consolidation. Avoid vibrator contact with reinforcement steel or formwork which causes steel displacement and transmits vibration through formwork potentially causing damage or displacement, maintaining 50-100mm clearance from steel and forms. For wall and column placement, insert vibrator at regular intervals as concrete lifts are placed, moving vibrator systematically across placement area ensuring complete coverage without missing areas. Work vibrator carefully around congested reinforcement areas where steel spacing is tight, using smaller diameter vibrator probes if standard probes cannot fit between bars. Monitor vibrator operation for any unusual sounds or performance indicating mechanical issues, immediately replacing faulty vibrators to prevent placement delays. Coordinate vibration work with concrete placement ensuring concrete is vibrated within 30 minutes of placement before initial set begins affecting vibrator effectiveness. Clean vibrator probes periodically during placement removing concrete buildup that affects probe performance and increases probe diameter hindering insertion into concrete.

Safety considerations

Wear hearing protection continuously during vibrator operation as noise levels typically exceed 100 dB(A) at operator position. Maintain secure footing while operating vibrator preventing slips on wet concrete that could cause falls onto reinforcement. Ensure vibrator electrical supply includes RCD protection for electric vibrators preventing electrocution if electrical faults develop. Monitor formwork for vibration-induced movement particularly when multiple vibrators operate simultaneously.

Screed Concrete Surface to Design Levels

Screed concrete surface to specified levels and grades using screeding equipment ranging from hand-pulled straight edges for small areas to laser-guided mechanical screeds for large slabs. For ground slab placement, establish screed rails or forms at specified slab elevation using laser level or surveyor's level, positioning rails to allow screeding in sections matching crew capacity and concrete workability timeframes. Pull or push screed along rails using see-sawing motion while advancing forward, working excess concrete ahead of screed while filling low spots behind screed with additional concrete. For laser-guided automated screeds, program screed receivers with design elevation data for different slab areas, allowing machine to automatically maintain specified levels as it advances across slab. Maintain consistent screed advance rate approximately 1-2 metres per minute allowing screed action to properly level concrete without leaving waves or valleys, adjusting rate based on concrete slump and screeding equipment. Work from one end of placement area systematically toward opposite end ensuring entire area is screeded before concrete begins to stiffen, coordinating screeding pace with concrete delivery rate. For elevated slabs without permanent screeding rails, use temporary screed supports or dead-man supports to establish screed elevation at intermediate points across slab width. Check screed accuracy periodically using straightedge or laser level verifying surface levels are within specified tolerance (typically ±5mm for standard slabs, ±2mm for high-tolerance floors). Correct any obvious high or low spots immediately during screeding when concrete is still workable, adding concrete to low areas and removing excess from high spots. For complex slab profiles including falls to drains or varied elevations, adjust screeding technique or use multiple screeding passes to achieve specified profiles. Clean screed blade periodically removing concrete buildup that affects screeding accuracy and increases dragging force required from workers.

Safety considerations

Screeding requires sustained awkward postures with bent spine positions creating high back injury risk, requiring rotation of screeding personnel every 30-45 minutes. Maintain stable footing during screeding to prevent slips on wet concrete or trips over reinforcement. For laser-guided screeds, ensure all workers aware of machine operating path to prevent workers being struck by moving equipment. Monitor workers for fatigue during sustained screeding work implementing mandatory rest breaks.

Perform Bull Floating and Initial Finishing

Begin initial finishing operations after screeding is complete using bull floats (long-handled floats) to smooth concrete surface, embed aggregate, and close surface texture in preparation for final finishing. Wait for initial surface water to evaporate or bleed water to be removed before bull floating, as working surface that is too wet brings excess water to surface creating weak surface layer. Push and pull bull float across concrete surface in overlapping passes using smooth sweeping motions, holding float handle at angle that keeps leading edge slightly raised preventing digging into concrete surface. Work bull float perpendicular to screeding direction filling any ridges or valleys left by screeding, achieving smooth uniform surface texture. For large slab areas, use mechanical bull float attached to power float machine allowing operator to cover large areas efficiently while reducing physical exertion compared to hand bull floating. Coordinate bull floating timing with concrete placement rate so that early-placed concrete receives bull floating before surface becomes too stiff for effective finishing, while later-placed concrete has adequate time for bleed water evaporation. After bull floating, allow concrete surface to further stiffen monitoring for proper finishing condition indicated by surface supporting worker weight without significant indentation (typically 4-6 hours after placement depending on temperature and concrete mix). Use knee boards or foot boards to distribute worker weight when accessing concrete surface before it achieves full hardness, preventing deep footprints that are difficult to remove. Remove any surface defects including footprints, tool marks, or debris embedment during this waiting period while concrete is still workable. Check surface periodically for readiness for final finishing by attempting to hand float small test area, proceeding with finishing when concrete is firm enough that hand float produces smooth closed surface without bringing excess water to surface.

Safety considerations

Bull floating requires repetitive overhead arm movements creating shoulder strain, requiring rotation of workers performing this task. Knee boards and foot boards become extremely slippery when wet with concrete, requiring careful weight distribution and slow movements to prevent slips. Workers must wear waterproof gloves even when using long-handled tools as concrete splatter contacts arms during bull floating.

Complete Power Troweling and Final Finishing

Perform final concrete finishing using power trowels and hand trowels achieving specified surface finish and density. Begin power troweling when concrete surface is sufficiently hardened to support power trowel weight without excessive indentation, typically 4-8 hours after placement depending on temperature, concrete mix, and required finish. Start with power trowel fitted with float pans (flat disc blades) for initial finishing pass working over entire slab area systematically, operating trowel at moderate speed and adjusting blade pitch to achieve smooth surface without bringing excess mortar to surface. Make subsequent troweling passes at progressively higher blade pitch angles and machine speeds, switching to steel finishing blades for final passes, typically requiring 3-5 total passes to achieve specified finish. For ride-on power trowels, operator follows systematic path across slab ensuring complete coverage without missing areas, overlapping passes by approximately 150mm preventing unfinished strips. Adjust troweling timing and intensity based on concrete hardness monitoring machine performance, as troweling too early when concrete is soft causes surface tearing while troweling too late when concrete is hard makes finishing difficult and may cause surface burning. Perform hand troweling for edges, corners, around columns, and other areas inaccessible to power trowels, using steel hand trowels to match finish achieved by power trowels in main slab areas. Apply progressive troweling pressure during hand finishing working from light initial passes to firm final passes, using smooth fluid motions keeping trowel blade flat against concrete surface. Create specified surface texture through final troweling pass, achieving high-gloss power troweled finish through multiple high-speed hard troweling passes, or stopping troweling earlier for moderate finish requirements. Edge concrete slabs using edging tool creating rounded edges at slab perimeter, control joints, and construction joints, preventing edge chipping and providing architectural appearance. Cut control joints using grooving tool at specified spacing while concrete is still plastic, or plan for sawcut joints to be cut after concrete hardens. Clean finishing tools regularly during operations preventing concrete buildup that mars surface finish.

Safety considerations

Power trowel operation exposes operator to noise levels typically 90-100 dB(A) requiring hearing protection throughout finishing operations lasting several hours. Ensure adequate ventilation if power trowel operates indoors as exhaust fumes from petrol engines cause carbon monoxide hazard in enclosed spaces. Hand troweling creates sustained wrist and shoulder strain from repetitive motions and pressure application, requiring work rotation. Concrete surface becomes very slippery when polished by power troweling, creating slip hazard for workers moving around slab edges.

Apply Curing Regime and Surface Protection

Implement appropriate concrete curing regime immediately after finishing operations are complete to promote proper strength development and prevent surface cracking from premature drying. For standard curing using curing compound, apply liquid membrane-forming curing compound to concrete surface using low-pressure sprayer ensuring uniform coverage rate per manufacturer specifications (typically 4-5 square metres per litre). Apply curing compound in two coats at right angles to each other ensuring complete surface coverage without holidays (missed areas), with first coat applied immediately after finishing and second coat 15-30 minutes later. Verify adequate curing compound application by checking for uniform appearance and continuous film formation, with any missed areas receiving additional application. For wet curing methods using hessian and water, place wet hessian or geotextile fabric over concrete surface keeping fabric continuously wet through regular water application for minimum 7 days curing period. Use plastic sheeting over wet hessian retaining moisture and reducing watering frequency required. For plastic sheet curing, place polyethylene plastic sheeting directly on concrete surface immediately after finishing, sealing joints between sheets and weighing down edges preventing moisture loss. Ensure plastic sheets remain in contact with concrete surface throughout curing period preventing air gaps that allow moisture evaporation. Protect concrete surface from traffic and construction activities during initial curing period, using barrier fencing or signage preventing premature loading before concrete achieves adequate strength. For hot weather conditions requiring enhanced curing, apply water fog spray or misting to cool concrete surface immediately after finishing, use reflective insulation blankets reflecting solar radiation, and extend curing duration to compensate for accelerated early strength gain and potential long-term strength reduction. For cold weather protection, install insulated curing blankets maintaining concrete temperature above 5°C minimum throughout initial curing period, using ground heaters or temporary enclosures if extreme cold is predicted. Monitor concrete temperature during curing period particularly for cold weather pours, recording temperatures and ensuring adequate protection is maintained. Schedule formwork stripping based on concrete strength development typically requiring minimum 7 days curing before slab formwork removal, with longer durations for columns, beams, and suspended structural elements supporting their own weight plus construction loads. Obtain approval from engineer or supervisor before permitting any construction traffic or material loading on newly placed concrete, verifying adequate strength has been achieved through cylinder testing or non-destructive maturity testing.

Safety considerations

Curing compound application requires adequate ventilation if spraying indoors, with solvent-based compounds producing harmful vapors. Wear appropriate respiratory protection if ventilation is inadequate, using organic vapor cartridge respirators. Wet concrete surfaces under plastic sheeting become extremely slippery creating fall hazard, requiring workers to avoid walking on covered areas. Verify concrete has achieved adequate strength before removing formwork support as premature stripping causes structural deflection potentially leading to slab collapse.

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Frequently asked questions

What qualifications do I need to supervise concrete placement operations?

Supervision of concrete placement operations requires combination of formal qualifications and practical experience ensuring supervisors can identify quality issues and safety hazards. The minimum qualification for concrete placement supervision is Certificate III in Concreting or equivalent trade certification, though many experienced concreters supervise based on extensive practical experience without formal qualifications if they can demonstrate competency. Principal contractors increasingly require Certificate IV in Building and Construction or Construction Management qualifications for leading hand positions with supervisory responsibility. Supervisors must understand concrete technology including mix design principles, workability requirements, strength development processes, and factors affecting concrete quality. Knowledge of Australian Standards particularly AS 3600 Concrete Structures and AS 1379 Specification and Supply of Concrete is essential for quality control decision-making. Supervisors should have practical experience across different concrete applications including slabs, columns, walls, and suspended structures, understanding specific placement and finishing requirements for each element type. First aid certification and construction white card are mandatory for all site personnel including supervisors. For high-risk construction work classification, supervisors must be able to prepare or review SWMS documentation, conduct pre-placement briefings, implement documented safety procedures, and respond appropriately to safety incidents. Many contractors provide internal training for supervisors covering company-specific procedures, quality control testing, documentation requirements, and safety management systems. The supervisor role includes coordination with other trades, liaison with engineers and project managers, quality control testing and documentation, crew management and task allocation, safety monitoring and enforcement, and problem-solving during placement operations, requiring practical judgment that only develops through experience.

How do I prevent cement burns during concrete finishing work?

Cement burn prevention requires multiple protective barriers and hygiene practices recognizing that wet concrete has pH 12-13 causing chemical burns through prolonged skin contact. The primary control is waterproof gloves specifically designed for cement work using nitrile or PVC coating extending minimum 300mm up forearms, providing effective barrier if maintained intact without coating damage. Gloves must be inspected before use and during work breaks, immediately replacing any gloves with tears, holes, or coating separation exposing skin. Cotton gloves are inadequate for wet concrete work as they absorb cement-laden water bringing alkaline solution into direct skin contact and should never be used for concrete placement or finishing. Long-sleeve cotton shirts under waterproof bib overalls or coveralls prevent cement splatter reaching arms and torso, with waterproof outer layer shedding concrete while cotton inner layer absorbs perspiration maintaining comfort. Waterproof rubber boots minimum 300mm height with sealed construction prevent cement water penetration that commonly causes severe burns to feet and lower legs, with boots inspected daily for cracks or separation allowing water entry. Immediate washing facilities positioned maximum 30 metres from concrete work areas allow rapid cement removal if concrete contacts skin through PPE failure or splash events, with the critical factor being washing within minutes before burns develop. Barrier creams (pre-work skin protection creams) applied to exposed skin before work provide additional protection creating sacrificial layer, though they supplement rather than replace gloves and protective clothing. Workers must be educated that cement burns develop slowly over hours making workers unaware of ongoing damage until serious burns develop, emphasizing prevention through consistent PPE use rather than relying on discomfort to indicate harmful exposure. End-of-shift full body washing removes any cement contamination that penetrated protective clothing, with particular attention to areas where clothing contacts skin. Any cement contact that causes skin redness, itching, or irritation must be immediately washed and reported to supervisor, with affected workers seeking medical assessment before continuing concrete work. Workers who develop cement dermatitis showing skin cracking, bleeding, or allergic reactions must be removed from cement contact until condition resolves, as continued exposure worsens condition and can cause permanent skin sensitization.

What is the maximum time from concrete batching to placement completion?

Time limits from concrete batching to placement completion ensure concrete maintains adequate workability for proper placement and consolidation while achieving specified strength and durability. Australian Standard AS 1379 specifies maximum delivery time of 90 minutes from adding water at batching plant to concrete discharge at site, though practical limits are often shorter based on ambient temperature and concrete mix characteristics. Hot weather with ambient temperatures exceeding 30°C accelerates cement hydration reactions reducing available placement time, with maximum batching-to-placement time reduced to 60 minutes in extreme heat unless concrete includes set-retarding admixtures extending workability. Cold weather below 15°C slows hydration allowing extended placement time up to 120 minutes before workability loss becomes problematic, though AS 1379 90-minute maximum still applies as quality assurance measure. Concrete containing set-retarding admixtures for extended workability can maintain adequate slump for 2-4 hours from batching depending on retarder dosage and temperature, allowing longer placement windows for complex pours where rapid placement is impractical. Project specifications may impose tighter time limits than AS 1379 minimums based on specific durability or quality requirements, with high-strength concrete mixes typically requiring more stringent time control. Slump testing at discharge verifies concrete remains within specification, with loads rejected if slump has decreased below minimum specified value indicating excessive water loss or premature stiffening. Practical placement timing requires concrete to be placed and consolidated before initial set begins, typically 2-4 hours after batching depending on temperature, with finishing work completed before final set typically 4-8 hours after batching. If unexpected delays occur during placement such as equipment breakdown or weather interruption, contact concrete supplier immediately to discuss options including increased retarder dosing in subsequent loads or placement of construction joints to segregate delayed concrete. Never add water to concrete at site to restore lost slump as this violates AS 1379 requirements and seriously compromises concrete strength and durability, instead rejecting loads that have exceeded workability timeframes.

How do I know if formwork is adequate before placing concrete?

Formwork adequacy verification before concrete placement prevents catastrophic formwork collapse through systematic inspection confirming formwork design and construction meet engineering requirements. The starting point is engineered formwork design prepared by structural engineer or specialist formwork engineer, specifying formwork components, support spacing, bracing requirements, maximum concrete placement rate, and maximum concrete head height, with design stamped by engineer accepting responsibility. Pre-placement inspection checklist based on engineering design covers formwork component condition checking for damage from previous use that could compromise strength, correct installation of formwork shores (vertical supports) at spacing matching design requirements with adequate load capacity, adequate bracing preventing lateral movement particularly for wall and column formwork resisting concrete pressure, secure formwork ties preventing formwork spreading under lateral concrete pressure and spaced per design, stable support base under formwork shores ensuring ground bearing capacity is adequate without settlement under load, proper formwork joint sealing preventing grout loss through gaps, clean formwork with release agent applied allowing subsequent stripping without damage, reinforcement steel properly positioned without formwork displacement, and safe access for concrete placement allowing workers to perform work without compromising formwork. Visual indicators of inadequate formwork include shores not bearing fully on support surfaces showing gaps, bracing members not properly fastened or only hand-tight without secure fixation, damaged formwork components showing cracks or splits, ground settling under shores creating visible subsidence, and formwork ties stretched or loose not providing adequate formwork restraint. Inspection must be conducted by competent person with formwork knowledge, typically qualified carpenter or formwork supervisor, who can identify deficiencies and verify conformance with engineering design. Critical items include shore capacity calculations confirming that shores can support concrete load plus construction live loads and dynamic loads from concrete placement, typically requiring engineers' safe load tables for proprietary shoring systems. The inspector signs off on formwork approval documenting that inspection is complete and formwork is adequate for concrete placement, with concrete trucks not dispatched until approval documentation is received. During concrete placement, competent person monitors formwork for any movement, unusual sounds indicating material stress, or visible deflection, with authority to immediately stop concrete placement if formwork issues develop.

What should I do if heat stress symptoms develop during concrete placement?

Heat stress during concrete placement requires immediate recognition and response preventing progression from early symptoms of heat exhaustion to potentially fatal heat stroke. Early heat stress symptoms include heavy sweating, fatigue, thirst, muscle cramps, headache, dizziness, and nausea, which workers often dismiss as normal work fatigue but actually indicate developing heat illness requiring intervention. If any worker exhibits these symptoms, immediately move them to shaded cool area away from concrete placement operations and work exertion, sitting them down or lying them flat if dizzy. Remove or loosen restrictive clothing including boots and gloves improving heat dissipation, and apply cooling measures such as cool wet towels to neck, armpits, and groin where major blood vessels allow efficient body cooling. Provide cool drinking water or electrolyte drinks having worker sip slowly rather than rapid consumption which can cause nausea, aiming for 500ml consumption over 15-20 minutes. Monitor affected worker continuously watching for symptom improvement or deterioration, with improvement indicated by reduced heart rate, decreased sweating, and subjective feeling of recovery. If symptoms do not improve within 15-20 minutes of rest and cooling, or if worker exhibits confusion, loss of consciousness, cessation of sweating despite heat, rapid breathing, or vomiting, these indicate progression to heat stroke requiring immediate emergency services notification via 000. Heat stroke is medical emergency requiring hospital treatment, with first aid focusing on aggressive cooling using any available means including cold water immersion if possible, while awaiting ambulance arrival. Continue cooling measures until emergency services arrive or worker core temperature is reduced, recognizing that rapid cooling prevents permanent organ damage or death. Other workers should not dismiss heat stress symptoms in colleagues as "weakness" or pressure affected workers to continue working, as heat stroke can develop rapidly with fatal outcome. After any heat stress incident, conduct incident investigation identifying contributing factors such as inadequate shade, insufficient water availability, lack of work-rest cycles, or pressure to complete placement without breaks, implementing corrective actions before resuming work. Workers recovering from heat stress should not return to full work duties same day even if they feel recovered, as heat stress susceptibility remains elevated for 24-48 hours after initial incident.

Can I add water to concrete at site if it seems too stiff?

Adding water to concrete at site is prohibited under Australian Standard AS 1379 and seriously compromises concrete strength and durability, making it unacceptable practice regardless of apparent concrete stiffness. Water-cement ratio is the fundamental factor controlling concrete strength, with every 10% increase in water content reducing concrete strength by approximately 15-20%, meaning unauthorized water addition can reduce concrete below specified strength creating structural adequacy concerns. Concrete specifications define target slump and acceptable slump range verified through testing at batching plant and on delivery, with slump loss during transport and placement anticipated in mix design. If concrete delivered to site has slump below specification minimum, the correct procedure is to reject the load returning it to batching plant rather than attempting to restore slump through water addition. Some concrete mixes include mid-range water-reducing admixtures that allow slump adjustment at site through admixture addition rather than water addition, but this is only permitted if specified in project concrete specification and performed by qualified concrete technician following documented procedures. Concrete that appears stiff may still be within specification slump range, requiring actual slump testing rather than visual assessment to verify compliance. High ambient temperature causes rapid slump loss through water evaporation, making hot weather concrete placement challenging but not justifying water addition. Proper response to slump loss includes using concrete within shorter timeframes, requesting concrete with higher initial slump to account for expected slump loss, using set-retarding admixtures to maintain workability for extended periods, or scheduling placements during cooler times of day reducing slump loss rate. For concrete that has partially set due to excessive time from batching or very high temperatures, no amount of water addition will restore workability and the load must be rejected. Any temptation to add water typically stems from time pressure to complete placement or avoid wasting concrete loads, but the quality consequences of water addition far exceed the inconvenience of load rejection. Project specifications typically include testing requirements for suspect concrete, which can include additional cylinder testing or coring of hardened concrete, with testing costs and any required remedial work charged to responsible party if unauthorized water addition is identified.

Overview

Concrete placement and finishing operations occur across diverse construction applications with techniques adapted for specific structural elements and finish requirements. Ground-level slab placement typically involves large volumes of concrete delivered by multiple trucks over several hours, with laser-guided screeding equipment achieving precise level tolerances and power trowels producing smooth trafficable surfaces. Elevated slab placement in multi-storey construction uses concrete pumps or crane-lifted kibbles to transport concrete vertically, with placement occurring in sections coordinated with formwork capacity and curing schedules. Column and wall placement requires careful concrete flow control preventing segregation while ensuring complete formwork filling without voids, using vibration equipment to consolidate concrete around dense reinforcement steel. Stair placement demands precise screeding to non-uniform profiles and surface finishing that provides slip-resistance while meeting architectural appearance standards. Specialized applications include exposed aggregate finishes requiring surface retarders and aggregate exposure timing, polished concrete requiring specific finishing techniques to facilitate mechanical polishing, and textured or patterned finishes using stamping tools or surface treatments applied during finishing operations. The work is performed by qualified concreters with trade certifications or extensive experience, working in crews typically comprising a leading hand coordinating placement sequencing, concreters operating screeds and finishing equipment, and laborers assisting with concrete spreading and material handling. Modern finishing equipment includes laser-guided screeding systems achieving 2mm level tolerance over 3-metre distances, ride-on power trowels for efficient finishing of large floor areas, and specialized tools for edge details and hard-to-reach locations. Environmental conditions significantly impact placement timing and techniques, with hot weather requiring early morning or evening placement schedules to avoid excessive concrete temperatures, cold weather requiring concrete heating or insulated curing blankets, and wet weather potentially requiring placement postponement to prevent concrete quality degradation. Quality control during placement includes slump testing to verify concrete workability, air content testing for freeze-thaw durability, temperature monitoring to ensure concrete remains within specified limits, and documentation of placement timing for strength development tracking. The work is classified as High Risk Construction Work under WHS Regulation 2011 when concrete placement is structural in nature or occurs at height, requiring documented SWMS and systematic risk management approaches.

Why This SWMS Matters

Concrete placement and finishing operations generate significant injury statistics in Australian construction with manual handling incidents causing chronic back injuries and musculoskeletal disorders, cement contact causing chemical burns and occupational dermatitis affecting hands and forearms, slips and trips on wet concrete surfaces resulting in falls and impact injuries, heat stress during sustained placement operations in Australian summer conditions causing heat exhaustion and occasionally fatal heat stroke, and noise exposure from concrete vibrators and power trowels exceeding 100 dB(A) contributing to hearing loss. Safe Work Australia data identifies concreting work among the highest-risk construction activities measured by injury frequency and severity, with time pressures related to concrete setting characteristics contributing to incident risk as workers rush to complete placement and finishing before concrete workability is exceeded. Recent prosecutions following concrete placement incidents have resulted in fines approaching $800,000, with inadequate SWMS documentation cited as contributing factor in multiple cases where injured workers were not following documented safe work procedures or where procedures failed to address known hazards. The legal requirement for comprehensive SWMS documentation stems from WHS Regulation 2011 classification of structural concrete work as high-risk construction work requiring written risk assessment and control measures before work commences. Principal contractors must ensure SWMS are prepared by competent persons with knowledge of concrete construction hazards and effective control measures, reviewed and approved before work commences, communicated to all workers involved in concrete placement, and monitored to ensure procedures are followed during operations. The Person Conducting a Business or Undertaking (PCBU) has ultimate responsibility for ensuring concrete work is performed safely, but concreters, subcontractors, and individual workers share responsibilities for following documented procedures and reporting unsafe conditions. Courts have repeatedly found that general construction experience does not satisfy competency requirements for SWMS preparation in specialized work such as concrete placement, requiring specific concreting knowledge and understanding of relevant Australian Standards including AS 3600 for concrete structures and AS 1379 for concrete specification. Beyond regulatory compliance and legal protection, effective concrete placement SWMS provide essential quality assurance ensuring concrete is placed, consolidated, and finished using techniques that achieve specified strength and durability outcomes. Inadequate consolidation leaves voids reducing structural capacity, improper finishing damages surface durability, incorrect curing results in surface cracking and reduced strength development, and poor sequencing can create cold joints affecting structural integrity. The economic consequences of concrete placement defects are substantial, potentially requiring costly remediation including concrete removal and replacement, or structural strengthening if defects affect load-carrying capacity. Insurance companies increasingly require documented SWMS for concrete operations as condition of cover, recognizing that systematic risk management correlates with reduced claims and better project outcomes.

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Risk Rating

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After ControlsLow

Key Controls

• Pre-start briefing covering hazards
• PPE: hard hats, eye protection, gloves
• Emergency plan communicated to crew

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Concrete Placement and Finishing Safe Work Method Statement

What this SWMS covers

Why this SWMS matters

Hazard identification

Manual Handling Injuries from Concrete Spreading and Finishing

Cement Burns and Dermatitis from Wet Concrete Contact

Slips, Trips and Falls on Wet Concrete Surfaces

Heat Stress During Sustained Concrete Placement Operations

Noise Exposure from Concrete Vibrators and Power Trowels

Formwork Overload and Collapse During Concrete Placement

Control measures

Mechanical Concrete Handling Equipment to Eliminate Manual Lifting

Comprehensive Skin Protection Program for Cement Exposure Prevention

Heat Stress Prevention and Management Program

Pre-Placement Formwork Inspection and Sign-Off System

Hearing Protection Program with Noise Monitoring

Personal protective equipment

Waterproof Nitrile-Coated Gloves Extended Cuff

Waterproof Rubber Boots with Steel Toe Cap

Long-Sleeve Shirt and Waterproof Bib Overalls

Class E Hard Hat

Hearing Protection Class 4-5

Safety Glasses with Side Shields

High Visibility Clothing Class D

Sun Protection Including Hat and Sunscreen

Inspections & checks

Before work starts

During work

After work

Step-by-step work procedure

Pre-Placement Preparation and Equipment Setup

Receive First Concrete Truck and Verify Mix Specification

Place and Spread Concrete into Formwork

Consolidate Concrete Using Vibration Equipment

Screed Concrete Surface to Design Levels

Perform Bull Floating and Initial Finishing

Complete Power Troweling and Final Finishing

Apply Curing Regime and Surface Protection

Frequently asked questions

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Overview

Why This SWMS Matters

Concrete Placement and Finishing SWMS Sample

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