Safe Work Method Statement

Concrete Floor Preparation

Comprehensive Australian WHS Compliant SWMS

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Comprehensive safety procedures for concrete floor preparation including grinding, scarifying, shot blasting, and surface profiling. This SWMS addresses critical hazards like silica dust inhalation, vibration injuries, and noise exposure with Australian WHS compliance requirements.

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Overview

What this SWMS covers

Concrete floor preparation involves mechanical treatment of concrete surfaces to achieve required profiles for flooring installations, coatings, or overlays. This includes diamond grinding, scarifying, shot blasting, and milling operations using heavy machinery that generates respirable crystalline silica dust and high vibration levels. Work is performed in industrial, commercial, and residential settings requiring specialized equipment, dust control systems, and personal protective equipment. Operations must comply with Australian standards for silica dust control and vibration exposure limits.

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Why this SWMS matters

Concrete floor preparation presents severe occupational health risks including respirable crystalline silica (RCS) dust causing silicosis and lung cancer, hand-arm vibration syndrome from power tools, and noise-induced hearing loss. According to Safe Work Australia, construction workers have elevated silica exposure risks, and vibration injuries affect thousands annually. This SWMS ensures compliance with the Work Health and Safety Act 2011 and the Managing Respirable Crystalline Silica Code of Practice 2022. Implementation prevents chronic diseases, protects workers from irreversible health damage, and demonstrates PCBUs' duty of care while ensuring high-quality surface preparation for subsequent flooring work.

Reinforce licensing, insurance, and regulator expectations for Concrete Floor Preparation 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

Silica Dust Inhalation

high

Grinding, scarifying, and shot blasting concrete releases respirable crystalline silica dust particles that can cause silicosis, lung cancer, and other respiratory diseases when inhaled. Concrete contains 25-70% crystalline silica depending on mix design.

Consequence: Chronic respiratory diseases, lung cancer, reduced lung function, and premature death from silica-related diseases.

Hand-Arm Vibration Syndrome

high

Prolonged use of grinding equipment, scarifiers, and power tools transmits vibration through hands and arms, causing vascular and neurological damage, loss of sensation, and reduced grip strength.

Consequence: Permanent nerve damage, loss of manual dexterity, chronic pain, and inability to perform fine motor tasks.

Noise Exposure

medium

Grinding and scarifying equipment generates high noise levels (90-110 dB) that can cause temporary or permanent hearing loss without proper protection.

Consequence: Noise-induced hearing loss, tinnitus, communication difficulties, and increased accident risk from inability to hear warnings.

Manual Handling Injuries

medium

Moving heavy equipment, hoses, and accessories requires lifting and carrying loads that can cause musculoskeletal injuries, particularly when working in awkward positions.

Consequence: Back injuries, shoulder strain, hernias, and long-term musculoskeletal conditions requiring medical treatment.

Electrical Hazards

medium

Power tools and extension cords present risks of electric shock, particularly when working with water suppression systems or in damp environments.

Consequence: Electric shock, burns, cardiac arrest, and death from electrocution.

Flying Debris and Particles

medium

Grinding operations can propel concrete particles, dust, and debris at high speeds, creating impact hazards to eyes and skin.

Consequence: Eye injuries, cuts, abrasions, and potential blindness from high-speed particle impacts.

Control measures

Deploy layered controls aligned to the hierarchy of hazard management.

Implementation guide

Water Suppression Systems

Engineering

Implement integrated water delivery systems that continuously supply water to cutting surfaces during grinding operations to suppress silica dust generation and capture airborne particles.

Implementation

1. Install water delivery systems on all grinding equipment 2. Maintain continuous water flow during cutting operations 3. Use water recycling systems to minimize water usage 4. Ensure water systems don't create electrical hazards 5. Monitor water quality to prevent equipment corrosion 6. Train operators on water system maintenance and troubleshooting

HEPA Vacuum Dust Collection

Engineering

Utilize high-efficiency particulate air (HEPA) vacuum systems rated M-Class or H-Class to capture silica dust at the source and prevent airborne dispersion.

Implementation

1. Use vacuum systems rated for silica dust collection 2. Ensure proper hose connections and seals 3. Position vacuum nozzles close to cutting surfaces 4. Maintain vacuum system filters and performance 5. Empty vacuum systems in controlled areas 6. Conduct regular maintenance and filter replacement

Anti-Vibration Tools and Practices

Engineering

Select low-vibration tools and implement vibration-dampening measures to reduce hand-arm vibration exposure and prevent vibration injuries.

Implementation

1. Choose equipment with vibration-dampening features 2. Use anti-vibration gloves and tool grips 3. Implement work rotation for extended tool use 4. Maintain equipment to minimize vibration 5. Monitor vibration exposure levels 6. Provide vibration-free breaks for operators

Exposure Monitoring and Air Quality Testing

Administrative

Conduct regular air quality monitoring for respirable crystalline silica and implement exposure controls based on monitoring results.

Implementation

1. Test concrete silica content before work begins 2. Monitor airborne silica levels during operations 3. Implement exposure reduction when levels exceed limits 4. Keep exposure records for regulatory compliance 5. Conduct health monitoring for exposed workers 6. Review and update controls based on monitoring data

Personal Protective Equipment

PPE

Provide comprehensive PPE for silica dust, vibration, noise, and impact protection during concrete floor preparation operations.

Implementation

1. Issue P2 or higher respiratory protection for silica work 2. Provide anti-vibration gloves for tool operation 3. Supply hearing protection rated for high noise levels 4. Ensure safety glasses with side protection 5. Provide long pants, long sleeves, and steel-capped boots 6. Supply high-visibility vests for site work

Equipment Maintenance and Inspection

Administrative

Maintain all equipment in safe working condition and conduct regular inspections to prevent mechanical failures and ensure effective dust control.

Implementation

1. Inspect all equipment before each use 2. Check dust control systems functionality 3. Verify electrical safety of power tools 4. Maintain cutting blades and grinding discs 5. Test emergency stop mechanisms 6. Document all maintenance and inspections

Download complete control procedures

Personal protective equipment

Respiratory Protection

Requirement: P2 particulate respirator or higher, meeting AS/NZS 1716 standards

When: Required for all concrete grinding, scarifying, and dust-generating work

Anti-Vibration Gloves

Requirement: Vibration-dampening gloves with impact protection

When: Required when operating vibrating tools for extended periods

Hearing Protection

Requirement: Ear muffs or plugs rated for 25-30 dB noise reduction

When: Required when operating grinding equipment over 85 dB

Safety Glasses/Goggles

Requirement: Impact-resistant eyewear meeting AS/NZS 1337

When: Required for all grinding and debris-generating operations

Steel-Capped Safety Boots

Requirement: Boots meeting AS/NZS 2210.3 with toe protection

When: Required at all times on construction sites

Protective Clothing

Requirement: Long pants, long sleeves, and high-visibility vest

When: Required for all concrete preparation work

Inspections & checks

Before work starts

✓Test concrete for silica content and document results
✓Inspect all grinding equipment and safety guards
✓Verify dust control systems are operational
✓Check electrical safety of power tools and cords
✓Assess ventilation requirements for enclosed spaces
✓Confirm availability of all required PPE
✓Review emergency procedures and evacuation routes
✓Check weather conditions and site access

During work

✓Monitor airborne silica dust levels continuously
✓Check dust control systems remain effective
✓Inspect equipment for vibration and overheating
✓Verify PPE condition and proper usage
✓Monitor noise levels and hearing protection compliance
✓Check for signs of fatigue in operators
✓Ensure proper waste containment and disposal
✓Monitor vibration exposure times for operators

After work

✓Inspect prepared surface for required profile and cleanliness
✓Check all equipment for damage and clean thoroughly
✓Verify proper disposal of silica-contaminated waste
✓Document any incidents or near-misses during work
✓Conduct equipment maintenance and storage
✓Clean work area and remove all debris
✓Complete exposure monitoring documentation
✓Review work procedures for improvement opportunities

Step-by-step work procedure

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

Field ready

Site Assessment and Planning

Conduct comprehensive site evaluation, test concrete silica content, and develop detailed preparation plan with dust control measures. Assess site conditions, access points, and environmental factors.

Safety considerations

Identify all silica sources and plan dust control measures. Ensure adequate ventilation and emergency access routes are available.

Equipment Setup and Testing

Set up grinding equipment, dust collection systems, and water suppression. Test all safety features, electrical connections, and control systems before commencing work.

Safety considerations

Verify all electrical equipment is grounded and GFCI protected. Test dust control systems to ensure they capture silica effectively.

Surface Cleaning and Preparation

Remove loose debris, clean surface contaminants, and prepare the concrete for mechanical treatment. Use appropriate cleaning methods without generating excessive dust.

Safety considerations

Use wet cleaning methods to minimize dust. Wear appropriate PPE during cleaning operations.

Concrete Grinding/Scarifying

Perform mechanical surface preparation using grinding equipment with continuous water suppression and dust collection. Work systematically across the surface achieving required profile.

Safety considerations

Maintain continuous dust control and monitor vibration exposure. Take regular breaks to prevent hand-arm vibration syndrome.

Surface Profiling and Quality Control

Measure surface profile using appropriate tools and verify the preparation meets specification requirements. Document surface condition and profile readings.

Safety considerations

Ensure measurement tools are used safely and don't create additional hazards. Verify surface doesn't have trip hazards.

Cleanup and Waste Disposal

Clean work area thoroughly, dispose of silica-contaminated waste according to regulations, and restore site to safe condition. Clean and maintain all equipment.

Safety considerations

Handle silica-contaminated waste as hazardous material. Ensure proper containment to prevent environmental contamination.

Documentation and Review

Complete all required documentation including exposure monitoring records, equipment inspections, and work completion reports. Review procedures for continuous improvement.

Safety considerations

Ensure all documentation is completed accurately and stored securely for regulatory compliance.

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Frequently asked questions

What is the workplace exposure standard for respirable crystalline silica?

The Australian workplace exposure standard for respirable crystalline silica (RCS) is 0.05 mg/m³ over an eight-hour time-weighted average. This limit must not be exceeded, and monitoring is required for work involving silica-containing materials.

How can silica dust exposure be eliminated during concrete grinding?

Silica dust can be controlled through engineering measures like integrated water delivery systems that continuously wet the cutting surface and HEPA vacuum dust collection systems. Respiratory protection is required when engineering controls cannot fully eliminate exposure.

What are the symptoms of hand-arm vibration syndrome?

Symptoms include tingling, numbness, loss of sensation in fingers, reduced grip strength, pain, and in advanced cases, blanching of the fingers (vibration white finger). Early recognition and cessation of exposure can prevent permanent damage.

How often should grinding equipment be inspected?

Equipment should be inspected before each use, with formal documented inspections conducted daily. Vibration levels, dust control systems, electrical safety, and mechanical integrity must be checked regularly.

What type of respiratory protection is required for silica work?

A minimum P2 particulate respirator is required, but higher protection (P3) may be needed depending on silica concentration. Full-face respirators with P3 filters are recommended for high-exposure tasks.

How should silica-contaminated waste be disposed of?

Silica-contaminated waste must be handled as hazardous material. It should be contained to prevent dust release, bagged securely, and disposed of through licensed waste management services following local environmental regulations.

Overview

Concrete floor preparation involves mechanical surface treatment to create suitable substrates for flooring installations, coatings, or overlays. This work includes diamond grinding, scarifying, shot blasting, and surface profiling using heavy machinery and power tools. Operations are commonly performed in industrial facilities, commercial buildings, warehouses, and preparation for epoxy coatings or new flooring systems. The work requires specialized equipment and generates significant dust and noise hazards.

Why This SWMS Matters

Concrete floor preparation presents severe health and safety risks including silica dust inhalation causing silicosis and lung cancer, vibration injuries leading to hand-arm vibration syndrome, and noise-induced hearing loss. Australian WHS data shows construction workers face elevated risks from silica exposure and vibration injuries. This SWMS ensures compliance with the Work Health and Safety Act 2011 and the Managing Respirable Crystalline Silica Code of Practice 2022. Proper implementation prevents chronic diseases, demonstrates PCBUs' duty of care, and protects workers from irreversible health damage while ensuring quality surface preparation.

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