Safe Work Method Statement for Formwork Installation, Inspection and Removal

Formwork Decks-Columns-Stairs Safe Work Method Statement

Comprehensive Australian WHS Compliant SWMS

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Formwork installation for concrete decks, columns, and stairs represents high-risk construction work requiring engineered design, systematic assembly procedures, and rigorous inspection to prevent catastrophic collapse incidents. Formwork systems support thousands of tonnes of wet concrete, reinforcement steel, and construction loads during placement and curing, with structural failure causing severe crush injuries, multiple worker fatalities, and major project delays. This work encompasses design and erection of horizontal formwork for suspended concrete slabs and decks using proprietary metal formwork systems or timber falsework, vertical formwork for concrete columns using reusable steel forms or custom timber boxing, and complex stair formwork integrating inclined stringers with tread and riser forming. Modern formwork practice employs sophisticated engineered systems including modular aluminum beams and adjustable props, climbing formwork for high-rise construction, and table forms for repetitive floor construction, alongside traditional timber formwork constructed on-site from plywood and dimensional lumber. This Safe Work Method Statement addresses the critical hazards in formwork operations including structural collapse from inadequate design or assembly, falls from height during erection and stripping, struck-by injuries from falling formwork components, manual handling injuries from heavy materials, and premature stripping before concrete achieves required strength. Compliance with AS 3610 Formwork for Concrete, Work Health and Safety Regulations classifying formwork as high-risk construction work, and engineering design requirements under AS 1576 Scaffolding ensures worker safety and structural integrity throughout the formwork installation, concrete placement, and removal cycle.

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Overview

What this SWMS covers

Formwork construction is a critical temporary works activity that creates the mould defining concrete structural element shapes and supporting immense loads during the critical period between concrete placement and sufficient strength development for self-support. The formwork industry has evolved from purely site-built timber construction to sophisticated proprietary systems combining aluminum beams, steel props, reusable formwork panels, and engineered connection systems optimized for rapid assembly and maximum reuse cycles. Understanding the distinctions between these formwork types is essential for selecting appropriate systems and implementing corresponding safety controls. Horizontal formwork for concrete decks and suspended slabs represents the most structurally demanding application, supporting dead loads from wet concrete typically 24 kN/m³, reinforcement steel adding 1.5-2 kN/m², formwork self-weight 0.3-0.5 kN/m², plus construction live loads from workers, equipment, concrete placement impact, and material storage commonly totaling 2.5-5 kN/m². A typical 200mm thick suspended slab generates approximately 7-9 kN/m² total load on formwork during construction, equating to 70-90 tonnes load on a 100 square metre slab area. Proprietary deck formwork systems use aluminum beams as primary spanning members supported on adjustable steel props at 1.2-1.5m centers, with formwork panels (typically 18-21mm plywood or aluminum) spanning between beams. Design calculations verify beam capacity, prop spacing, and foundation bearing capacity prevents overload collapse. Table forms consisting of large pre-assembled formwork panels on wheeled frames enable entire floor sections to be formed, poured, and stripped as single units, dramatically increasing construction speed on buildings with repetitive floor layouts. Column formwork differs fundamentally from deck formwork by supporting lateral concrete pressures rather than primarily vertical loads. Fresh concrete behaves as a fluid generating hydrostatic pressure proportional to placement height and pour rate, with rapid column pours creating pressures approaching 60-100 kN/m² on formwork faces. Column forms must resist these lateral pressures plus forces from concrete vibration without deflecting excessively or failing. Proprietary steel column forms with built-in ties and walers dominate commercial construction, available in standard sizes and rapidly assembled using pin or wedge connections. Columns requiring non-standard sizes or complex shapes use custom-built plywood forms with substantial timber or steel waling and external bracing. The critical design consideration is formwork tie spacing and capacity, as ties resist the enormous forces trying to burst formwork outward during concrete placement. Stair formwork combines complexity of both horizontal and vertical systems, requiring precise dimensional control to achieve comfortable stair geometry while supporting concentrated loads on inclined members. Stair forms typically consist of inclined timber stringers (typically 150x50mm or larger dimension lumber) supporting individual tread and riser forms constructed from plywood and timber blocking. The inclined nature creates additional forces requiring careful bracing and connection design. Prefabricated steel stair formwork systems simplify erection and improve dimensional accuracy but require careful planning to match specific stair dimensions. Landing areas integrate with stair flights requiring coordinated design and construction. Formwork design is governed by AS 3610 Formwork for Concrete, which mandates design by qualified persons (typically structural engineers) for formwork supporting loads exceeding 10 kN or spans greater than 3 metres. Design documentation must include formwork layout drawings showing prop positions and spacings, design calculations verifying structural adequacy, material specifications for formwork components, maximum concrete pour rates and placement sequence, and minimum concrete strength before stripping. This documentation is required before formwork erection commences and must be available on-site during construction for reference and inspection.

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Why this SWMS matters

Formwork failure represents one of the most catastrophic construction incidents, typically occurring during concrete placement when loads reach maximum values and multiple workers are present on and below formwork. Australian construction industry incident data shows formwork collapses cause multiple worker fatalities annually with single incidents claiming 3-5 lives when entire deck formwork systems fail suddenly dropping workers and wet concrete from height. The sudden, catastrophic nature of formwork failure provides virtually no warning and no opportunity for escape. Workers positioned below formwork during concrete placement are struck by falling concrete weighing many tonnes causing crush injuries incompatible with survival. Those working on formwork surface experience sudden drops of 3-4 metres or more onto lower building levels or ground with severe impact trauma and burial under wet concrete and formwork debris. Prosecutions following formwork collapse incidents have resulted in fines exceeding $2 million for principal contractors, formwork subcontractors, and designers who failed to adequately design, construct, inspect, or supervise formwork operations. Courts have consistently found that formwork collapse incidents are entirely preventable through proper design, quality construction, systematic inspection, and adherence to design limitations regarding concrete pour rates and sequences. The 2012 Grocon formwork collapse at Swanston Street Melbourne resulted in three worker fatalities and led to successful prosecution with findings that inadequate formwork design, modification of formwork without engineering approval, and failure to implement adequate inspection procedures directly contributed to the tragedy. This case established precedents regarding duty of care for formwork safety extending from designers through principal contractors to site supervisors and formwork carpenters. The high-risk construction work classification for formwork under WHS Regulations imposes specific requirements beyond standard construction safety measures. These include mandatory Safe Work Method Statements prepared before work commences, formwork designs by competent persons with qualifications in structural engineering, design documentation available on site for inspection, competent supervision during erection and concrete placement, systematic pre-pour inspection and sign-off by qualified persons, and strict adherence to specified concrete placement rates and sequences. Regulator site inspections commonly focus on formwork operations during concrete placement, with immediate stop-work notices issued for deficient formwork lacking adequate design documentation, inadequate props or bracing, modified systems without engineering approval, or premature stripping before concrete achieves specified strength. Fall from height hazards during formwork erection and stripping frequently cause serious injuries even when formwork structural integrity is adequate. Formwork carpenters work at the leading edge of deck formwork installing beams and panels where conventional edge protection cannot be installed without interfering with work. Working above 2 metres height requires fall protection using catch platforms, safety mesh, travel restraint systems, or personal fall arrest equipment. Formwork stripping creates particular fall risks as removal of formwork panels and beams progressively eliminates the working surface requiring careful sequencing and temporary platforms for safe access. Falls from formwork typically occur onto concrete surfaces or reinforcement steel causing severe trauma including spinal injuries, head trauma, and impalement on reinforcement projections. Manual handling injuries are endemic in formwork operations due to the repetitive handling of heavy components including formwork beams weighing 15-30kg, steel props weighing 10-25kg depending on extended height, plywood panels weighing 20-40kg, and column form panels weighing 30-60kg. Formwork carpenters handle hundreds of individual components daily during erection and stripping cycles, with cumulative loading causing chronic musculoskeletal disorders affecting backs, shoulders, and knees. The work often occurs in awkward positions including overhead beam installation, kneeling to install props, and reaching to position panels. Time pressures to complete formwork erection ready for scheduled concrete placement drives rushed work and poor lifting techniques. Team lifting and mechanical handling aids are frequently overlooked due to perceived time inefficiency despite their effectiveness in preventing injuries.

Reinforce licensing, insurance, and regulator expectations for Formwork Decks-Columns-Stairs 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

Formwork Structural Collapse During Concrete Placement

High

Formwork collapse represents the ultimate catastrophic failure scenario in concrete construction, occurring when formwork structural capacity is exceeded by loads imposed during concrete placement. Collapse causes include inadequate initial design with undersized beams or insufficient props, incorrect assembly with props omitted or improperly positioned, foundation failure beneath props where ground bearing capacity is inadequate, modifications to formwork layout without engineering approval reducing structural capacity, premature stripping before concrete achieves design strength, and excessive concrete placement rates or impact loading exceeding design assumptions. Collapses typically occur suddenly without warning when critical component reaches ultimate capacity, triggering progressive failure as adjacent members become overloaded. The enormous mass of wet concrete (typically 100-300 tonnes for a modest building floor) falls from height carrying workers, equipment, and formwork debris. Workers positioned below formwork have no escape opportunity and suffer fatal crush injuries. Those on formwork surface fall multiple levels experiencing severe impact trauma and burial under concrete.

Consequence: Multiple worker fatalities from crush injuries and burial under wet concrete. Severe trauma injuries to survivors including spinal fractures, head injuries, and limb amputations. Prosecution of builders and formwork contractors with fines exceeding $2 million. Project delays of months while incident investigation occurs and failed formwork is removed. Permanent business damage from loss of contractor licenses and industry reputation.

Falls from Height During Formwork Erection and Stripping

High

Formwork carpenters work at leading edges of deck formwork systems installing beams, panels, and props at heights typically 3-6 metres above lower floor levels or ground. Working at the edge while positioning heavy components creates fall risks from overbalancing, stepping back while handling materials, or losing footing on formwork beams. Conventional edge protection including guardrails cannot be installed until formwork construction reaches the slab perimeter, leaving workers exposed during critical early erection phases. Formwork stripping operations require workers to dismantle edge protection first to access formwork components, then progressively remove formwork panels and beams that constitute their working surface, creating continuously evolving fall hazards. Stairs formwork erection requires working on inclined surfaces making falls more likely. Working from ladders to install column forms above ground level introduces additional fall risks. Falls from formwork typically result in impacts onto concrete slab edges, reinforcement steel projections, or props causing severe injuries. Night work or early morning starts in poor lighting conditions exacerbate fall risks by reducing visibility of gaps, edges, and tripping hazards.

Consequence: Fatal falls from heights above 4 metres striking hard concrete or steel surfaces. Spinal fractures causing paraplegia or quadriplegia. Traumatic brain injuries from head strikes. Impalement injuries from landing on reinforcement steel projecting from previous concrete pours. Fractures of limbs requiring surgical repair and extended rehabilitation. Permanent disability preventing return to construction work.

Struck-by Injuries from Falling Formwork Components

High

Formwork components dislodged during erection, adjustment, or stripping operations fall from height striking workers below causing severe impact injuries. Formwork beams weighing 15-30kg falling from deck height achieve significant kinetic energy capable of causing fatal head injuries or fractures. Props knocked over during assembly or collapse of partially erected formwork strike workers in fall path. Column form panels topple when inadequately braced during assembly striking nearby workers. Formwork materials stored at slab edges can be knocked off by workers or equipment falling onto areas below. Concrete placement operations using skips or kibbles create risk of concrete bucket striking formwork or props causing displacement and component falls. Deliberate dropping of formwork components from height during stripping operations injures workers in landing zones. Wind loading on erected formwork before concrete placement can dislodge inadequately secured panels or entire form sections. Crane-lifted formwork panels swinging uncontrolled during hoisting strike formwork carpenters positioning components. The unpredictable nature of struck-by incidents means workers may be struck without warning from above while focused on tasks.

Consequence: Fatal head injuries from components striking workers' heads. Fractured skulls and severe concussions causing permanent brain damage. Broken limbs and joints requiring surgical repair. Crush injuries to feet and hands from dropped beams and panels. Spinal injuries from torso strikes by falling props. Secondary injuries from falls caused by workers being struck while working at height.

Manual Handling Injuries from Heavy Formwork Components

Medium

Formwork installation requires repetitive manual handling of heavy components with individual formwork beams weighing 15-30kg, steel props 10-25kg, plywood panels 20-40kg, and column form panels 30-60kg. Formwork carpenters typically handle several hundred individual components during erection of a single floor deck, creating substantial cumulative loading on musculoskeletal system. Awkward working positions are inherent in formwork operations including working overhead to install beams onto bearer positions, kneeling or squatting to position and extend props, reaching across gaps to position panels, and working in confined spaces beneath low formwork. Team lifting is frequently required for heavy components but communication difficulties and mismatched lifting timing can increase injury risk. Repetitive impact loading occurs when components are dropped onto formwork decks or tapped into position using hammers. Work is often performed at rapid pace driven by construction program requirements to complete formwork ready for scheduled concrete placement. Fatigue accumulates over long work shifts common in formwork operations (10-12 hour days are typical) reducing workers' ability to use proper lifting technique.

Consequence: Chronic lower back injuries including disc damage requiring surgery and causing permanent work restrictions. Shoulder rotator cuff injuries from overhead work and reaching requiring extended time off work. Knee damage from prolonged kneeling and squatting on hard surfaces. Acute back strains from single heavy lifts or awkward lifts causing immediate severe pain and inability to continue working. Cumulative trauma disorders affecting hands and wrists from repetitive impact loading.

Premature Formwork Stripping Before Adequate Concrete Strength

High

Premature removal of formwork before concrete achieves sufficient strength to support self-weight plus construction loads causes structural failure of newly cast concrete. AS 3610 specifies minimum concrete strength requirements before formwork removal, typically minimum 15 MPa for vertical formwork (columns, walls) and minimum 75% of design strength for horizontal formwork supporting structural loads (slabs, beams). Achieving these strengths requires time for concrete curing dependent on concrete mix design, ambient temperature, and structural element size. Pressure to accelerate construction schedules drives premature stripping decisions. Inadequate concrete strength testing or reliance on assumed curing times rather than measured strengths leads to stripping before adequate strength development. Cold weather substantially extends strength gain period with concrete placed at 10°C requiring twice the curing time compared to 20°C placement. Structural elements with high design loads including long-span beams and cantilevers require higher concrete strengths before formwork removal compared to simple slabs. Premature stripping causes concrete deflection, cracking, or complete structural collapse of recently poured elements requiring expensive repairs or demolition and reconstruction.

Consequence: Structural collapse of recently poured concrete causing worker fatalities and serious injuries. Permanent structural damage requiring demolition and reconstruction at enormous cost. Delayed project completion due to repairs or reconstruction. Prosecution for breach of AS 3610 requirements and WHS duties. Loss of structural integrity requiring extensive assessment and strengthening of damaged elements. Client litigation for defective construction.

Inadequate Formwork Design Documentation and Load Capacity

High

Formwork design inadequacy creates structural collapse risks through undersized components, excessive spans between supports, inadequate connections, or foundation failures beneath props. AS 3610 requires formwork design by competent persons (qualified structural engineers) for any formwork with loads exceeding 10 kN or spans greater than 3 metres, covering virtually all commercial formwork applications. Design must consider all load cases including concrete dead load, reinforcement weight, formwork self-weight, construction live loads from workers and equipment, concrete placement impact forces, and lateral concrete pressure for vertical forms. Many formwork failures result from using formwork supplier 'standard' configurations without project-specific engineering verification that the configuration is adequate for actual imposed loads. Modifications to formwork layout made on-site without engineering approval commonly cause collapses when critical support positions are altered. Inadequate ground conditions beneath props cause bearing capacity failures particularly after rain when ground softens. Lack of design documentation means inspectors cannot verify formwork as-built condition matches design intent. Re-use of damaged formwork components reduces capacity below original design assumptions.

Consequence: Formwork collapse causing multiple worker fatalities and severe injuries. Prosecution of builder and designer for failure to provide adequate formwork design with fines exceeding $1 million. Permanent business damage including loss of contractor license. Professional disciplinary action against engineers approving inadequate designs. Project abandonment due to loss of confidence in construction quality.

Uncontrolled Concrete Placement Exceeding Formwork Design Limits

Medium

Concrete placement operations that exceed formwork design assumptions regarding pour rate, placement sequence, or construction loading create collapse risks even when formwork is adequately designed for normal placement. Rapid concrete placement generates dynamic impact loading and higher formwork pressures exceeding design values. Simultaneous placement across entire deck area creates maximum loading when design may assume progressive placement with concrete beginning to set in earlier-poured areas. Material stockpiling on formwork including reinforcement steel bundles, concrete buggies, and equipment concentrates loads exceeding distributed live load allowances. Skip or kibble concrete placement creates severe impact loading when concrete is dumped rather than smoothly placed. Excessive workers on formwork simultaneously during placement concentrates construction live loads. Concrete pump boom resting on formwork or slab edge during placement adds concentrated loads not considered in design. These uncontrolled loading conditions can exceed formwork capacity even when basic design is adequate.

Consequence: Formwork overload collapse during concrete placement causing worker fatalities. Partial formwork failure creating dangerous deflections and cracking requiring emergency propping. Project delays while engineers assess formwork capacity and implement remedial measures. Additional costs for emergency propping and strengthening. Damage to formwork components requiring replacement before re-use.

Control measures

Deploy layered controls aligned to the hierarchy of hazard management.

Implementation guide

Engineered Formwork Design by Qualified Structural Engineer

Elimination

Comprehensive formwork design by qualified structural engineers eliminates collapse risks by ensuring formwork components, connections, and foundations have adequate capacity for all imposed loads. Design process begins with load determination including concrete dead load (typically 24 kN/m³ for normal weight concrete), reinforcement weight (1.5-2 kN/m²), formwork self-weight (0.3-0.5 kN/m²), construction live loads (minimum 2.5 kN/m² per AS 3610), and dynamic impact allowances for concrete placement. For deck formwork, design calculations verify formwork beam bending and shear capacity, prop compression capacity and buckling resistance, connection adequacy, and ground bearing capacity beneath props. For column formwork, lateral concrete pressure calculations consider pour height, concrete density, placement rate, and vibration effects, with design verifying formwork tie spacing and capacity, waler member capacity, and bracing adequacy. Design output includes detailed drawings showing formwork layout with all critical dimensions, prop spacing and positions, beam spans and sizes, material specifications, maximum concrete placement rates, and minimum concrete strength before stripping. Formwork design eliminates trial-and-error assembly and ensures structural adequacy through engineering analysis.

Implementation

1. Engage qualified structural engineer registered in relevant state to prepare formwork design for all projects involving structural concrete 2. Provide engineer with project drawings showing concrete element geometry, reinforcement details, and specified concrete strength 3. Identify available formwork equipment inventory including beam sizes, prop capacities, and panel types for engineer to incorporate in design 4. Engineer performs load calculations including all dead loads, live loads, impact factors, and safety factors per AS 3610 5. Engineer verifies component capacities against calculated loads identifying any equipment limitations requiring alternative approaches 6. Engineer prepares formwork layout drawings showing prop positions, beam spans, panel layout, and critical dimensions 7. Design drawings include maximum concrete placement rates and sequences preventing formwork overload 8. Design documentation specifies minimum concrete strength before formwork removal for different element types 9. Engineer provides site attendance during initial formwork erection verifying installation matches design intent 10. All formwork designs signed and sealed by engineer and retained on-site for inspection and reference during construction

Systematic Pre-Pour Formwork Inspection and Approval

Administrative

Comprehensive formwork inspection before concrete placement approval prevents collapse by verifying formwork as-built condition matches design requirements and identifying defects requiring correction. Inspection checklist addresses all critical formwork elements including verification props are positioned per design drawings with no missing props, prop base plates are properly positioned on firm bearing surface with adequate load distribution, formwork beams are correctly positioned and secured, panels are tight-jointed without gaps allowing concrete leakage, connections including beam-to-prop and panel-to-beam connections are properly made using correct fittings, bracing is installed per design particularly for column forms, no damaged components are used, and no unauthorized modifications have been made to approved design. Inspection is performed by competent person having knowledge of formwork design requirements and authority to prevent concrete placement if deficiencies exist. Written inspection record documents inspection date, inspector name and qualifications, formwork areas inspected, any deficiencies identified, and corrective actions completed before approval. No concrete placement proceeds until inspector provides written approval that formwork is acceptable and matches design requirements. The inspection process provides final verification before critical loading phase.

Implementation

1. Develop formwork inspection checklist based on AS 3610 requirements and project-specific design documentation 2. Designate competent person to perform inspections having relevant formwork experience and understanding of design requirements 3. Schedule inspection minimum 24 hours before planned concrete placement allowing time for deficiency correction 4. Inspector verifies formwork layout matches design drawings measuring prop positions and beam spans 5. Check all props are vertical, properly extended, secured with pins, and bearing on base plates on firm ground 6. Verify formwork beams are correctly positioned and secured to props without excessive deflection 7. Inspect all panels for damage, proper jointing, and adequate securing to beams 8. Check column forms for adequate ties, walers, and bracing per design specifications 9. Identify and document any deficiencies requiring correction before concrete placement approval 10. Issue written formwork approval sign-off only after all deficiencies corrected and formwork verified acceptable

Fall Protection Systems for Working at Height on Formwork

Engineering

Comprehensive fall protection prevents formwork worker injuries and fatalities during erection and stripping operations at height. Fall protection hierarchy follows AS 1657 Work Platform Design starting with passive systems requiring no worker action including temporary safety mesh installed under formwork providing catch protection for falls through formwork deck, perimeter scaffolding providing edge protection and safe working platform for formwork erection at slab edges, and catch platforms positioned below work areas catching falls before significant drop distance. For situations where passive protection is impracticable, active fall protection systems include industrial safety nets meeting AS 1891 installed below formwork deck, temporary handrail systems attached to formwork beams providing edge protection that can be progressively relocated as work proceeds, and personal fall arrest systems using full-body harnesses connected to horizontal lifelines or fixed anchor points. Fall protection must be in place before workers are exposed to fall hazards, with progressive installation as formwork erection proceeds rather than retrospective installation after exposure has occurred. Stripping operations require fall protection maintained until workers complete work at height, with temporary platforms or mobile elevated work platforms providing safe access to formwork components being removed.

Implementation

1. Review formwork erection sequence identifying all locations and phases where workers will be exposed to falls from 2 metres or greater height 2. Design fall protection system matching work sequence with preference for passive systems not requiring worker action 3. Install safety mesh under formwork decking during erection creating catch system for falls through incomplete deck 4. Erect perimeter scaffolding with guardrails providing edge protection and safe working platform for formwork assembly at building edges 5. Install catch platforms below work areas where other protection methods are impracticable 6. For active fall protection, install horizontal lifeline systems on formwork beams allowing harness connection during edge work 7. Provide industrial safety nets below formwork deck as backup protection for workers not continuously connected to fall arrest 8. Train all formwork workers in fall protection system use including harness fitting, anchor point selection, and emergency procedures 9. Inspect all fall protection components daily before use checking for damage or deterioration requiring replacement 10. Maintain fall protection throughout stripping operations using mobile platforms or temporary scaffolding for safe access to formwork being removed

Controlled Concrete Placement Procedures Limiting Pour Rate and Loading

Administrative

Systematic concrete placement controls prevent formwork overload by limiting pour rates, placement sequences, and construction loading to design assumptions. Concrete placement plan prepared before pouring specifies maximum placement rate (typically 3-5 metres vertical height per hour for columns, or progressive placement across deck areas), placement sequence proceeding from one end of deck to other allowing earlier concrete to begin setting before full deck load applied, maximum concrete buggy or wheelbarrow numbers on formwork simultaneously limiting construction live loads, pump boom positioning avoiding support on formwork or slab edges creating concentrated loads, and material stockpile limitations preventing reinforcement or equipment accumulation on formwork. Pour rate control is particularly critical for column forms where rapid placement generates high lateral concrete pressures exceeding formwork tie capacity. Continuous monitoring during placement observes formwork for any deflection, movement, or distress requiring immediate work stoppage and engineering assessment. Designated formwork supervisor with authority to stop concrete placement if any safety concerns arise provides critical oversight during high-risk placement phase.

Implementation

1. Prepare concrete placement plan before pouring specifying maximum pour rates, placement sequences, and loading limitations based on formwork design 2. Conduct pre-pour toolbox meeting with all concrete placement crew explaining placement plan, pour rate limits, and formwork loading restrictions 3. Designate formwork supervisor to monitor formwork condition throughout placement with authority to stop work if concerns arise 4. Limit concrete placement rate for columns to maximum 3 metres height per hour preventing excessive lateral pressures on formwork 5. Sequence deck concrete placement progressively from one end allowing earlier-placed concrete to begin setting reducing formwork loads 6. Restrict maximum number of concrete buggies on formwork simultaneously preventing concentrated construction live loads 7. Position pump boom to discharge concrete directly into placement areas without bearing on formwork or slab edges 8. Prohibit stockpiling of materials including reinforcement, tools, or equipment on formwork during concrete placement 9. Monitor formwork continuously during placement observing for any deflection, prop movement, or formwork distress 10. Stop concrete placement immediately if any formwork problems observed and assess formwork condition before recommencing

Concrete Strength Testing Before Formwork Stripping Authorization

Administrative

Mandatory concrete strength verification before formwork removal prevents premature stripping and structural failure of newly cast concrete. AS 3610 specifies minimum concrete strengths before formwork removal based on element type and loading conditions. For vertical formwork (columns, walls), minimum 15 MPa strength is typically required before stripping, usually achieved within 12-24 hours in normal temperature conditions. For horizontal formwork supporting loads (beams, slabs, cantilevers), minimum 75% of specified 28-day strength is required before removing props and formwork, potentially requiring 7-14 days or longer in cold weather. Strength verification uses test cylinders cast from concrete batches during placement, cured alongside structural elements, and tested using compression testing machines at specified ages. Alternatively, non-destructive testing methods including rebound hammer tests or maturity meter monitoring provide in-situ strength estimation. Formwork stripping must not proceed until test results confirm adequate strength has been achieved. Design engineer may impose more stringent requirements than AS 3610 minimums for complex structures or high loads.

Implementation

1. Cast minimum three concrete test cylinders from each 50 cubic metres of concrete placed or each floor level, whichever is less 2. Cure test cylinders alongside structural elements in similar temperature conditions preventing false strength indications 3. Mark test cylinders clearly identifying concrete batch, element location, and casting date 4. Transport cylinders to NATA-accredited testing laboratory for compression testing at specified ages 5. Review formwork design documentation identifying minimum required concrete strength before stripping for each element type 6. Schedule cylinder testing to align with planned formwork stripping timing allowing results before stripping commences 7. Verify test results meet or exceed minimum required strengths before authorizing formwork removal 8. If tests indicate inadequate strength, delay stripping and conduct additional testing at later age until requirements met 9. For temperature-sensitive projects, use maturity meters embedded in concrete providing real-time strength estimation 10. Document all strength test results and stripping approvals in project quality records demonstrating compliance with AS 3610

Mechanical Handling Equipment for Formwork Components

Engineering

Mechanical handling equipment eliminates manual handling injuries by reducing worker physical effort during formwork erection and stripping. Equipment includes telehandlers or forklifts equipped with formwork beam lifting attachments enabling mechanical placement of beams at height, crane-mounted formwork panel lifters handling large panel assemblies as single units, trolley systems running on formwork beams for horizontal material transport across deck areas, vacuum lifters for panel positioning eliminating manual carrying, and scaffold hoists providing material lifting to upper floor levels. Larger formwork systems including table forms and climbing formwork incorporate integral mechanical handling with hydraulic lifting and positioning systems. The mechanical handling approach requires advance planning to ensure equipment access is available, formwork components are compatible with mechanical handling attachments, and work procedures coordinate mechanical and manual operations safely. Benefits extend beyond injury prevention to improved productivity and quality through more precise component positioning. Initial equipment investment is offset by reduced labor costs and workers' compensation savings.

Implementation

1. Review formwork erection plan identifying all heavy component handling operations suitable for mechanical assistance 2. Procure or hire appropriate mechanical handling equipment including telehandlers with formwork attachments and material hoists 3. Ensure site layout provides adequate access for mechanical handling equipment to formwork work areas 4. Design formwork systems to facilitate mechanical handling using standard beam lengths and panel sizes compatible with lifting equipment 5. Provide formwork beams with lifting eyes or attachments compatible with telehandler beam lifters 6. Use table forms or large panel assemblies for repetitive floors enabling crane lifting of complete formwork sections 7. Install trolley systems on formwork beams for horizontal material distribution across large deck areas 8. Train formwork crews in mechanical handling equipment operation and load rigging procedures 9. Develop mechanical handling procedures specifying equipment selection, rigging methods, and communication protocols between equipment operators and formwork crews 10. Inspect all mechanical handling equipment and lifting attachments daily before use verifying safe working order

Download complete control procedures

Personal protective equipment

Full-Body Fall Arrest Harness

Requirement: Full-body harness meeting AS/NZS 1891.1 with front and rear D-rings, chest harness with connecting points for fall arrest lanyard, fitted with energy absorbing lanyard meeting AS/NZS 1891.4 maximum 2 metre length

When: Required for all workers performing formwork erection or stripping operations at heights above 2 metres where passive fall protection systems are not installed or do not provide adequate protection. Must be worn continuously when exposed to fall risks and connected to suitable anchor points or horizontal lifeline systems.

Safety Helmet with Chin Strap

Requirement: Type 1 industrial safety helmet meeting AS/NZS 1801 with four-point suspension system and chin strap preventing dislodgement, designed for head protection from falling objects and impact with fixed objects

When: Mandatory for all workers in formwork erection areas at all times due to risk of falling formwork components. Chin strap must be worn and fastened when working at height preventing helmet loss during falls or when working in positions where helmet could dislodge.

Safety Footwear with Ankle Support

Requirement: Steel toe-capped safety boots meeting AS/NZS 2210.3 with penetration-resistant sole, ankle support to reduce ankle sprains on uneven formwork surfaces, and slip-resistant sole suitable for walking on formwork beams

When: Required at all times in formwork work areas to protect feet from dropped formwork components, crushing injuries from props and beams, and penetration from protruding nails or reinforcement steel. Ankle support is particularly important when walking on formwork beams and working on uneven surfaces.

High-Visibility Clothing

Requirement: Class D day-only or Class D/N day-night high-visibility garment meeting AS/NZS 4602.1 with minimum 0.2 m² combined area of fluorescent and retro-reflective material

When: Required at all times in formwork areas where mobile plant including cranes, forklifts, and concrete pumps are operating to ensure worker visibility to plant operators. Particularly critical during crane lifting operations of formwork panels and concrete placement using pump trucks.

Work Gloves for Splinter and Cut Protection

Requirement: Leather or synthetic palm work gloves providing protection against splinters from timber formwork, cuts from sharp panel edges, and abrasion during handling of formwork components

When: Required during all formwork handling operations including erection, adjustment, and stripping to protect hands from splinters, cuts, and abrasions from formwork materials. Gloves must allow adequate dexterity for tool operation and connection assembly while providing protection.

Hearing Protection

Requirement: Class 4 or 5 earmuffs or class 4 or 5 earplugs meeting AS/NZS 1270 providing minimum 25dB noise reduction

When: Required when working around concrete placement operations using pump trucks, concrete vibrators, or when using power tools for formwork cutting and adjustment. Must be worn when noise levels exceed 85 dB(A) during sustained operations.

Inspections & checks

Before work starts

✓Verify formwork design documentation is available on-site including layout drawings, design calculations, and engineer's signed approval
✓Check ground conditions beneath formwork installation area ensuring firm bearing surface adequate for prop loads
✓Inspect all formwork components to be used including beams, props, panels, and connections verifying good condition without damage
✓Verify adequate formwork materials and components are available for planned installation preventing delays and improvisation
✓Check fall protection equipment including harnesses, lanyards, anchor points, and safety mesh is available and in good condition
✓Confirm crane or mechanical handling equipment is available and operational for lifting formwork components to required heights
✓Review formwork erection sequence plan with work crew ensuring all workers understand installation sequence and safety requirements
✓Verify concrete placement schedule to ensure formwork completion timeframe is realistic without requiring rushed work
✓Check weather forecast for strong winds that could affect formwork stability during erection or create fall risks

During work

✓Monitor formwork installation against design drawings verifying prop positions and spacing match engineering requirements
✓Check prop base plates are properly positioned on firm ground with adequate bearing area distributing loads
✓Verify all props are vertical and properly extended with securing pins installed preventing collapse
✓Inspect formwork beam positioning and connections ensuring beams are properly secured to props
✓Check panels are properly positioned and secured with tight joints preventing concrete leakage
✓Verify column formwork ties are installed at correct spacing with adequate tightening preventing formwork burst
✓Monitor workers for proper fall protection use including harness wearing and lanyard connection when exposed to fall risks
✓Observe manual handling practices identifying two-person lift opportunities and use of mechanical handling aids
✓Check for proper housekeeping with formwork materials stored safely preventing tripping hazards or components falling from height

After work

✓Conduct final comprehensive formwork inspection before concrete placement using detailed checklist covering all critical elements
✓Verify formwork layout matches design drawings with all required props installed in correct positions
✓Check all connections are properly made and secured including beam-to-prop connections and panel-to-beam fixing
✓Inspect column formwork for adequate number of ties, proper waler installation, and sufficient bracing
✓Verify no damaged or defective components have been used in formwork assembly
✓Confirm fall protection systems are complete and functional protecting all workers who will be present during concrete placement
✓Check formwork is clean and free from debris that could contaminate concrete or create voids
✓Verify formwork inspector has signed approval document authorizing concrete placement to proceed
✓Confirm concrete placement plan is understood by concrete crew including maximum pour rates and placement sequence
✓Document formwork inspection completion with photographic records of critical areas before concrete placement commences

Step-by-step work procedure

Give supervisors and crews a clear, auditable sequence for the task.

Field ready

Review Formwork Design Documentation and Site Preparation

Begin formwork operations by thoroughly reviewing engineering design documentation prepared by qualified structural engineer. Design package includes formwork layout drawings showing prop positions, beam spans, panel layout, and all critical dimensions, design calculations verifying component capacities and safety factors, specifications for formwork materials and components, maximum concrete placement rates and sequences, and minimum concrete strengths before formwork stripping. Verify understanding of design requirements conducting walk-through with engineer if clarification needed regarding complex details or special requirements. Prepare site area where formwork will be installed by leveling ground beneath formwork installation areas ensuring firm bearing surface for prop base plates, removing debris and obstacles that could interfere with formwork erection, establishing material storage areas for formwork components within crane or telehandler reach of installation area, and installing access scaffolding or platforms providing safe working access to elevated formwork areas. Mark out formwork layout on lower floor slab or ground using string lines or chalk establishing reference points for prop positioning per design drawings. Mobilize all required formwork materials to site verifying adequate quantities of beams, props, panels, and connections are available before erection commences preventing delays and improvisation during installation.

Safety considerations

Design document review ensures formwork installation will follow engineering requirements preventing collapse from incorrect assembly. Site preparation provides firm, stable ground conditions for prop support preventing bearing failure. Material staging reduces manual handling distances and ensures adequate components available preventing improvised solutions. Layout marking enables accurate prop positioning per design requirements. Access scaffold installation provides safe working platforms preventing fall risks during formwork erection.

Install Formwork Props and Primary Beam System

Begin formwork erection by installing adjustable steel props at positions specified on formwork design drawings. Position prop base plates on firm ground ensuring adequate bearing area and verify ground will not settle under load. Extend props to approximate required height using prop extensions and adjust to achieve exact height required for formwork beam support. Ensure props are vertical checking with spirit level on two perpendicular faces and install prop heads ready to receive formwork beams. Secure props in extended position using locking pins preventing collapse from accidental release of extension mechanisms. Install primary formwork beams (typically aluminum beams spanning 3-5 metres between prop rows) positioning beams on prop heads and securing with beam-to-prop connections per manufacturer instructions. Verify beam positions match design layout and beams are level across width of formwork. For deck spans requiring multiple beam rows, install all primary beams progressively working across formwork area. Position secondary beams perpendicular to primary beams if design requires two-way beam system for longer spans. Check all beam connections are properly made with locking mechanisms engaged. Verify beam deflection is within acceptable limits (typically maximum L/360 under self-weight) by sighting along beams and measuring if necessary.

Safety considerations

Prop installation on firm ground prevents bearing failure and formwork collapse. Vertical prop alignment prevents buckling under load. Locking pin installation prevents props collapsing during erection. Beam-to-prop connection verification ensures components remain connected under load. Working from scaffolding or mobile platforms during beam installation prevents fall risks. Using mechanical handling equipment for beam placement reduces manual handling injuries. Two-person lift coordination for manual beam handling prevents individual overexertion.

Install Formwork Panels and Jointing

Install formwork panels (typically 18-21mm formwork plywood or reusable aluminum panels) onto beam system starting from one corner and progressively working across formwork area. Position panels carefully ensuring tight butt joints between adjacent panels preventing concrete leakage during placement. Secure panels to underlying beams using specified fixing methods which may include clips, screws, or panel lock systems depending on formwork type. Verify panel joints are properly supported by beams beneath preventing panel deflection causing poor concrete surface finish. For large deck areas, install panels in strips allowing workers to traverse installed panels to reach further areas rather than working from ladders or unsupported positions. Install edge formwork around slab perimeter creating containment for concrete and providing fixing for edge protection systems. Check formwork surface is level and smooth using long straight-edge and spirit level, making adjustments to prop heights as needed to achieve specified slab thickness and level. Apply formwork release agent to panel surfaces facilitating formwork removal after concrete curing. Install any required formwork inserts, blockouts, or penetrations per architectural and services drawings ensuring accurate positioning. Clean formwork surface removing any debris that could contaminate concrete or create surface defects.

Safety considerations

Progressive panel installation working from previously installed areas prevents falls from working on incomplete formwork. Panel securing prevents displacement during concrete placement. Edge formwork installation enables fall protection system attachment. Working from established formwork deck rather than ladders provides stable working platform. Release agent application prevents formwork bonding to concrete enabling safe removal. Housekeeping of panels and debris prevents trip hazards.

Install Column Formwork and Bracing

For column formwork, begin by establishing column position and dimensions using set-out marks on lower slab. Install column base ensuring precise positioning and secure fixing to lower slab preventing displacement during concrete placement. Assemble column formwork panels around column reinforcement steel using either prefabricated steel column forms or site-built plywood and timber forms. For prefabricated forms, connect panel sections using wedge or pin connections per manufacturer instructions, progressively assembling form around column perimeter. For site-built forms, construct formwork using plywood sheets supported by timber or steel walers at vertical spacing calculated to resist lateral concrete pressure (typically 300-600mm centers depending on pour rate). Install formwork ties through column formwork connecting opposing faces and resisting lateral concrete pressure. Ties must be installed at spacing specified in formwork design with adequate tightening to prevent formwork spreading during placement. Install external bracing to column formwork providing stability against lateral forces and preventing formwork movement during concrete placement. Bracing typically consists of timber or steel braces connecting formwork to floor slab at multiple points around column perimeter. Verify column formwork is plumb checking on two perpendicular faces using long spirit level or plumb bob. Make final adjustments to achieve specified plumb tolerance (typically 1:500). Install column formwork top cap or pouring opening enabling concrete placement while containing formwork during filling.

Safety considerations

Secure column base fixing prevents formwork toppling during assembly creating struck-by hazards. Progressive panel assembly builds stable formwork reducing collapse risks. Adequate formwork tie installation and tightening prevents formwork burst during concrete placement. External bracing prevents formwork collapse from impacts or lateral loads. Plumb verification ensures proper formwork positioning preventing rework. Working from scaffolding around columns prevents fall risks during erection above ground level.

Erect Stair Formwork Assembly

Stair formwork construction begins with installation of inclined stringer members (typically 150x50mm or larger timber) spanning from lower landing level to upper landing and supporting individual tread and riser forms. Mark stringer positions on landing formwork or structural concrete establishing stair width and alignment. Cut stringers to correct length and angle matching stair rise and run geometry using circular saw with accurate angle settings. Install stringers securing at both ends to landing formwork or edge beams ensuring adequate fixing strength to support concrete loads. For longer stair flights, intermediate support bearers may be required supporting stringers at mid-span preventing excessive deflection. Install individual riser boards (typically 18-21mm plywood cut to correct height) vertically between stringers creating containment for each concrete tread. Secure risers to stringers using screws or nails ensuring tight fit preventing concrete leakage. Install blocking between risers supporting formwork against lateral concrete pressure during placement. Verify stair geometry including rise height consistency (all risers within 5mm of each other) and going distance (all treads equal). Install edge formwork along stair sides defining stair width and providing containment. Brace stair formwork to prevent movement during concrete placement using diagonal braces connecting to stable structural elements or temporary scaffolding. Apply release agent to all formwork surfaces. Install any required stair nosing inserts or non-slip strips per specifications.

Safety considerations

Secure stringer fixing at both ends prevents formwork collapse during concrete loading. Adequate stringer size and support prevents deflection causing poor stair geometry. Riser securing prevents formwork spreading during placement. Bracing prevents formwork movement creating unsafe working conditions. Working from scaffolding during stair formwork erection prevents fall risks on inclined surfaces. Dimensional checking ensures stair geometry meets building code requirements preventing rework. Release agent application enables safe formwork removal.

Conduct Pre-Pour Formwork Inspection and Approval

Minimum 24 hours before planned concrete placement, conduct comprehensive formwork inspection using detailed checklist based on formwork design requirements and AS 3610 specifications. Inspection systematically verifies all critical formwork elements starting with prop positioning checking all props are installed at positions shown on design drawings with no missing props, measuring prop spacing to verify compliance with maximum spacings specified in design. Verify all props are vertical, properly extended to correct height, and secured with locking pins. Check prop base plates are positioned on firm ground with adequate bearing area. Inspect formwork beams verifying correct beam positions, adequate overlap at splices, proper beam-to-prop connections, and no visible deflection under self-weight. Check formwork panels are properly positioned with tight joints, adequate securing to beams, and no damaged panels used. For column formwork, verify correct number and spacing of formwork ties, adequate waler installation, proper external bracing, and formwork plumb within tolerance. Identify any formwork modifications made from design requiring engineering review and approval. Document all inspection findings including photographs of critical areas. Prepare written inspection report listing any deficiencies requiring correction before concrete placement authorization. Notify responsible formwork supervisor of deficiencies requiring immediate correction. Re-inspect corrected areas verifying acceptable remedial work. Issue written formwork approval only after all deficiencies corrected and formwork verified to match design requirements.

Safety considerations

Systematic inspection prevents formwork collapse by identifying and correcting deficiencies before critical loading occurs. Documentation creates accountability and verification trail. Deficiency notification ensures responsible persons are aware of problems requiring correction. Re-inspection verifies corrections are adequate. Written approval establishes formal authorization before high-risk concrete placement commences. Independent inspector verification provides quality assurance beyond formwork crew self-inspection.

Formwork Monitoring During Concrete Placement and Stripping Authorization

During concrete placement operations, designated formwork supervisor continuously monitors formwork condition observing for any signs of distress including visible deflection of formwork beams or panels, prop movement or tilting, formwork joint opening, column formwork tie stretching or breaking, unusual noises indicating component failure, and ground settlement beneath props. Monitor concrete placement rate and sequence verifying conformance with design specifications and placement plan. Use direct communication between formwork supervisor and concrete pump operator enabling immediate placement stoppage if formwork problems observed. If any formwork distress is detected, immediately stop concrete placement and evacuate all workers from on and below formwork to safe locations. Assess formwork condition in consultation with structural engineer determining if additional propping or bracing is required before placement continues. After concrete placement completion, formwork remains in place supporting concrete during strength development. Cast concrete test cylinders from each major concrete element for strength testing at specified ages. Arrange cylinder testing at appropriate times (typically 7 and 28 days) to verify concrete strength development. Review formwork design documentation identifying minimum required concrete strength before formwork removal for each element type. When test results confirm adequate strength achieved, authorize formwork stripping to proceed systematically removing panels, beams, and props in sequence preventing damage to concrete or unsafe exposure of inadequately supported concrete. Retain props under structural elements per design requirements until full design strength achieved.

Safety considerations

Continuous monitoring enables early detection of formwork problems preventing catastrophic collapse. Immediate work stoppage and evacuation in response to distress signs protects workers from collapse. Engineering assessment ensures any formwork problems are professionally evaluated. Strength testing verification prevents premature stripping and structural failure. Systematic stripping sequence prevents damage to new concrete. Retention of props until adequate strength achieved prevents structural overload of immature concrete.

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Frequently asked questions

Who is qualified to design formwork for commercial construction projects?

AS 3610 Formwork for Concrete requires formwork design by competent persons for any formwork with loads exceeding 10 kN or spans greater than 3 metres, which covers virtually all commercial formwork applications. Competent persons are typically qualified structural engineers registered with relevant state professional engineering boards (Engineers Australia members or equivalent). The engineer must have specific knowledge of formwork design principles, loading conditions, material properties, and connection capacities. For simple residential formwork with limited spans and loads, experienced formwork supervisors may be considered competent provided they have relevant qualifications and demonstrated formwork design experience. However, for multi-story commercial buildings, complex architectural features, or any formwork supporting significant loads, registered structural engineer design is essential and provides critical professional indemnity insurance protection. Design documentation must be signed and sealed by the responsible engineer and retained on-site for inspection by workers, supervisors, and safety regulators. Using standard formwork supplier configurations without project-specific engineering verification is inadequate and creates collapse risks when site conditions differ from supplier assumptions.

What inspection is required before concrete can be placed on formwork?

AS 3610 requires comprehensive formwork inspection by a competent person before concrete placement is authorized to proceed. Competent persons for formwork inspection include qualified engineers, experienced formwork supervisors with relevant training, or construction supervisors who understand formwork design principles and can verify installation matches design requirements. Inspection uses detailed checklist covering all critical formwork elements including verification all props are installed at positions shown on design drawings, props are vertical and properly secured with locking pins, prop base plates are on firm ground with adequate bearing, formwork beams are correctly positioned and secured, panels are tight-jointed and properly fixed, column formwork has correct number and spacing of ties, adequate bracing is installed per design, no damaged components are used, and no unauthorized modifications have been made to approved design. Inspection must be documented with written inspection report signed by inspector and noting any deficiencies requiring correction. Photographic records of critical formwork areas before concrete placement provide valuable documentation. Concrete placement must not proceed until inspector provides written approval that formwork is acceptable. This inspection represents the final quality control check before the high-risk concrete placement phase.

How long must formwork remain in place before it can be safely removed?

Formwork removal timing is governed by AS 3610 which specifies minimum concrete strengths before stripping based on element type and structural loading. For vertical formwork including column and wall forms, minimum 15 MPa concrete compressive strength is typically required, usually achieved within 12-24 hours in normal temperature conditions (20-25°C). For horizontal formwork supporting loads (beams, slabs, decks), formwork must remain in place until concrete achieves minimum 75% of specified 28-day design strength, which may require 7-14 days or longer depending on concrete mix design and temperature conditions. Cold weather substantially extends strength gain, with concrete placed at 10°C requiring approximately twice the curing time compared to 20°C placement. Props supporting long-span beams or highly loaded structural elements may require retention until full design strength is achieved at 28 days. Strength verification uses compression testing of concrete test cylinders cast from placement batches and cured alongside structural elements. Formwork must not be removed until test results confirm adequate strength. Alternatively, maturity meter monitoring or non-destructive testing methods can verify in-situ concrete strength. Formwork designers may specify stripping requirements more stringent than AS 3610 minimums for complex structures, and these design requirements take precedence. Never base stripping decisions on assumed curing times without actual strength verification as this creates serious risks of structural collapse.

What fall protection is required for workers erecting formwork at height?

Fall protection requirements for formwork erection follow the hierarchy of controls in AS 1657 Work Platform Design and WHS Regulations. First preference is elimination or passive fall protection systems including temporary safety mesh installed under formwork decking providing catch protection for falls through incomplete formwork, perimeter scaffolding with guardrails providing edge protection and safe working platform for formwork assembly at slab edges, catch platforms positioned below work areas, and industrial safety nets meeting AS 1891. Where passive systems are impracticable, active fall protection including personal fall arrest systems using full-body harnesses meeting AS/NZS 1891.1 connected to horizontal lifeline systems or fixed anchor points is required. Formwork workers must be trained in fall protection equipment use, harnesses must be correctly fitted, and workers must remain connected to anchor points whenever exposed to falls of 2 metres or greater. Work positioning systems allowing hands-free work while supported by harness and lanyard are preferred for tasks requiring both hands. Travel restraint systems preventing workers reaching fall edges provide simplified protection for specific situations. Fall protection must be installed progressively as formwork erection proceeds, not retrospectively after exposure. During formwork stripping, fall protection must remain in place using temporary platforms or mobile elevated work platforms providing safe access to formwork components being removed. Common violation is workers working at leading edges without fall protection during initial formwork erection when passive systems are not yet established.

Can formwork design be modified on-site to address unexpected conditions?

Site modifications to approved formwork designs create serious collapse risks and are prohibited without formal engineering review and approval. Common unauthorized modifications include omitting props to create access space or avoid obstacles, increasing prop spacing to reduce material requirements, substituting different beam sizes when specified components are not available, and modifying column formwork tie spacing or positions. Each of these changes can critically reduce formwork capacity below required levels causing collapse during concrete placement. If site conditions require formwork design changes, work must stop and formal variation process initiated including notification to design engineer of proposed changes and reasons, engineering analysis of proposed modifications verifying adequate capacity is maintained, preparation of revised formwork drawings showing approved modifications, and documentation of modification approval before work proceeds. Simple rule is that any deviation from approved formwork design requires engineering approval. Site supervisors and formwork carpenters should never make design decisions or approve modifications as they typically lack structural engineering knowledge to assess capacity implications. Emergency modifications may seem necessary when concrete placement is imminent, but proceeding with inadequate formwork creates unacceptable collapse risks. Delaying concrete placement pending proper engineering assessment is always the correct decision when formwork adequacy is questioned. Prosecution of contractors following formwork collapses commonly finds that unauthorized site modifications were contributing factors to failures.

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Key Controls

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

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Formwork Decks-Columns-Stairs Safe Work Method Statement

What this SWMS covers

Why this SWMS matters

Hazard identification

Formwork Structural Collapse During Concrete Placement

Falls from Height During Formwork Erection and Stripping

Struck-by Injuries from Falling Formwork Components

Manual Handling Injuries from Heavy Formwork Components

Premature Formwork Stripping Before Adequate Concrete Strength

Inadequate Formwork Design Documentation and Load Capacity

Uncontrolled Concrete Placement Exceeding Formwork Design Limits

Control measures

Engineered Formwork Design by Qualified Structural Engineer

Systematic Pre-Pour Formwork Inspection and Approval

Fall Protection Systems for Working at Height on Formwork

Controlled Concrete Placement Procedures Limiting Pour Rate and Loading

Concrete Strength Testing Before Formwork Stripping Authorization

Mechanical Handling Equipment for Formwork Components

Personal protective equipment

Full-Body Fall Arrest Harness

Safety Helmet with Chin Strap

Safety Footwear with Ankle Support

High-Visibility Clothing

Work Gloves for Splinter and Cut Protection

Hearing Protection

Inspections & checks

Before work starts

During work

After work

Step-by-step work procedure

Review Formwork Design Documentation and Site Preparation

Install Formwork Props and Primary Beam System

Install Formwork Panels and Jointing

Install Column Formwork and Bracing

Erect Stair Formwork Assembly

Conduct Pre-Pour Formwork Inspection and Approval

Formwork Monitoring During Concrete Placement and Stripping Authorization

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Formwork Decks Columns Stairs SWMS Sample

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