Risers Working In Safe Work Method Statement

Confined space classification for riser shafts depends on specific characteristics assessed against confined space definition in WHS Regulations. A confined space is an enclosed or partially enclosed space not designed or intended primarily for human occupancy, where there is risk of one or more of: harmful airborne contaminants, oxygen deficiency or enrichment, flammable atmosphere, or engulfment. Additionally, confined spaces typically have restricted entry and exit, and present difficulty for emergency rescue. Many riser shafts meet these criteria requiring formal confined space procedures, while some larger shafts with good access and ventilation may not require confined space classification. Indicators suggesting confined space classification include shaft access through small doors typically 600-900mm wide creating restricted entry/egress, vertical shaft configuration with limited natural ventilation particularly in internal building core locations, potential for atmospheric hazards from welding fumes, solvent vapors from pipe jointing work, or oxygen displacement by heavier-than-air gases, shaft dimensions less than 2 metres wide and of substantial vertical height creating enclosed feeling, and difficulty conducting emergency rescue particularly in vertical shafts requiring specialized retrieval equipment. Where any doubt exists, treat shaft as confined space implementing formal entry procedures rather than assuming it is safe. For shafts classified as confined spaces, implement comprehensive entry procedures including written confined space entry plan specific to shaft configuration, atmospheric testing before each entry measuring oxygen (19.5-23%), combustible gases (below 5% LEL), and toxic gases including carbon monoxide from any combustion equipment and volatile organic compounds from solvent-based joining materials, continuous forced ventilation using portable fans with ducting creating air exchange throughout shaft, continuous atmospheric monitoring using fixed gas monitors or periodic re-testing minimum every 2 hours during extended work, standby person stationed outside shaft access maintaining constant contact with workers inside via two-way radio or voice communication, written entry permit system documenting atmospheric test results, workers entered, standby person details, and completion sign-off, and emergency rescue procedures and equipment appropriate to vertical shaft configuration potentially including tripods with mechanical retrieval systems, full-body harnesses with vertical retrieval lines, or fire brigade notification for specialized confined space rescue capability. Brief all workers on confined space hazards, entry procedures, emergency signals, and prohibition of solo entry. Never enter shaft to attempt rescue without proper equipment and backup as secondary casualties commonly occur in confined space rescue attempts. For larger riser rooms or service areas with good access doors, adequate natural or mechanical ventilation, and no specific atmospheric hazards, confined space classification may not apply but general height safety and other hazard controls still apply. Document confined space assessment rationale whether classifying as confined space or determining it does not meet criteria, as this demonstrates due diligence in hazard assessment.

Floor penetrations for risers create serious fall hazards requiring protection under WHS Regulations which specify that floor openings exceeding 200mm in any dimension must be protected by covers capable of supporting anticipated loads, or by guardrails where covers are not practicable. For riser installations, protection requirements depend on penetration size and use frequency. For individual pipe penetrations typically 150-300mm diameter, fabricated covers provide most practical protection using minimum 12mm plywood or steel plate sized to overlap penetration minimum 150mm all sides providing adequate bearing on solid floor around opening. Covers must be capable of supporting minimum 200kg point load accounting for possibility of workers stepping onto covered opening unaware it is not solid floor. Install cleats or framing under cover preventing warping and ensuring rigidity. Mark covers prominently with high-visibility paint (typically yellow and black diagonal stripes) and large text "FLOOR OPENING" or "HOLE" clearly visible ensuring workers recognize covered opening rather than assuming solid floor. Secure covers preventing displacement using bolts through pre-drilled holes into floor, weighted placement using concrete blocks or steel sections on cover surface, or clips engaging floor or penetration edge. Covers must be in place whenever penetration is not in active use - for riser work requiring frequent pipe passing through penetrations, covers remove during active work but must be replaced immediately when work ceases including lunch breaks, shift end, and any period when workers are not actively using penetration. Daily site inspections must verify all penetrations are protected overnight. For large service shaft openings exceeding 1 metre in any dimension where covers are impractical due to size, weight, or frequent access requirements, install temporary guardrails around full penetration perimeter using scaffolding components or purpose-built guardrail systems. Guardrails must be minimum 900mm high with mid-rail approximately 450-500mm height and toe boards minimum 150mm high preventing materials rolling into opening. Guardrails must be fixed securely to floor or structural elements capable of resisting horizontal force of minimum 200N applied at top rail. For penetrations that are actively used for material passing with covers removed, establish exclusion zones using temporary barriers positioned back from penetration preventing inadvertent approach by workers not directly involved in pipe passing work. Paint high-visibility markings on floor surface around penetrations providing additional visual warning of hazard location visible when covers are temporarily removed. Implement cover management protocols designating responsibility for cover replacement - typically the last worker to use penetration is responsible for replacing cover before leaving area, with supervisor conducting verification checks. Brief all workers who access riser areas on penetration locations, protection requirements, and prohibition of removing covers except when specifically necessary for pipe work. Document penetration protection with site plans showing penetration locations, photographs of protected penetrations, and inspection records verifying ongoing protection compliance. For construction projects under principal contractor control, principal contractor typically establishes site-wide floor penetration protection standards that riser installation must comply with including cover specifications, marking requirements, and inspection schedules. Remember that falls through floor penetrations have caused fatalities and serious injuries on construction sites - consistent rigorous protection of all penetrations throughout construction period is critical safety requirement not optional administrative detail.

Fire penetration seals around riser pipes passing through fire-rated floors and walls are critical building fire safety elements regulated under Building Code of Australia (BCA) which requires fire-rated construction elements to maintain their fire resistance rating when penetrated by services. For multi-storey buildings, floor slabs typically have fire resistance level (FRL) ratings of 60/60/60 to 120/120/120 (structural adequacy/integrity/insulation in minutes), and penetrations through these floors must maintain equivalent fire resistance. Penetration seal systems comprise products installed in annular gap between pipe and penetration edge that expand when exposed to fire, sealing gap and preventing fire and smoke passage. BCA recognizes several evidence of suitability pathways for penetration seals with most common being products holding CodeMark certification demonstrating compliance through testing to AS 1530.4 or AS 4072.1, or products with assessment reports from accredited testing laboratories. Seal product selection must account for multiple factors including pipe material (different products for steel, copper, PVC, composite pipes as material behavior in fire differs substantially), pipe diameter (products specify maximum and minimum pipe diameters), floor or wall fire resistance level required (seal must achieve equal or greater FRL), and installation configuration (different products for floor versus wall penetrations, and whether single pipe or multiple pipes in one penetration). Installation must comply exactly with product manufacturer specifications including annular gap dimensions (typically 10-25mm but varies by product), seal thickness achieving required FRL, installation technique such as packing density for intumescent materials or spray application parameters for spray-applied products, and any additional components such as backing materials or surface treatments. Installer requirements vary by jurisdiction but increasingly building certifiers require installers to hold manufacturer approval or accreditation for specific products being installed, as this ensures installer competency and maintains product warranties and certifications. Some manufacturers operate formal approved installer programs providing training and certification with installation by non-approved installers potentially voiding product certification. For critical installations in large projects, consider engaging fire protection specialists holding specific fire penetration sealing credentials. Installation timing is important - seals must install after pipes are in final position as seal removal and reinstallation typically voids certification, but before building elements that would prevent future access are installed such as shaft wall lining. Building certifier inspection typically occurs at holding point after seal installation but before concealment allowing verification of compliant installation and opportunity to correct deficiencies. Documentation requirements include maintaining product data sheets and CodeMark certificates for all seal products used, photographs showing each penetration before, during, and after seal installation, penetration schedule listing every sealed penetration with location, pipe type and diameter, seal product used, installer details, and date of installation, installer declarations certifying installation per manufacturer specifications, and certifier sign-off after inspection confirming compliant installation. Provide complete seal documentation to building certifier for building certification file and to building owner for building operating manuals and future maintenance reference. Seal compliance failures can result in building occupancy delays pending rectification, certifier orders requiring exposure of sealed penetrations for inspection at contractor expense if compliance cannot otherwise be verified, requirement to remove non-compliant seals and reinstall using correct products and approved installers, and in worst cases removal of services and structural penetration modification if seal compliance cannot be achieved with existing penetration configuration. Prevention through careful product selection, use of approved installers, and building certifier engagement before concealment avoids costly rectification. Remember that fire seal integrity directly affects building occupant safety in fire events - unsealed or improperly sealed penetrations allow fire and smoke spread between floors potentially trapping occupants and causing casualties, making this not merely administrative compliance but critical life safety issue.

Effective communication between workers at different floor levels during riser installation is critical safety requirement preventing struck-by incidents, crushing injuries, and dropped object incidents that occur when workers perform uncoordinated simultaneous actions. Unlike normal work where workers can see each other and coordinate visually, multi-level riser work separates workers by floor slabs preventing visual contact and requiring deliberate communication systems. Implement comprehensive communication protocols beginning with providing two-way radio equipment to all workers involved in riser installation - specify dedicated radio channel for riser work team preventing interference from other site communications and ensuring clear reception. Establish standard verbal communication signals used consistently for all vertical material movements including "Ready to lift" requiring "Ready" acknowledgment from all workers at all levels involved before lifting commences, "Lifting now" announced by initiating worker as lift begins, "Stop" as immediate cessation command if any worker identifies hazard, "Set down" when item reaches destination and is positioned safely, and "Secure" confirmation from receiving worker that item is properly secured and lifting worker can release. Require positive acknowledgment of all communications - sending worker must receive verbal confirmation from all receiving workers before proceeding, not assumption of readiness from silence. Before any vertical material movement or activity affecting other levels, conduct verbal roll-call with workers at each level confirming position and readiness. Implement work zone designation within vertical shafts prohibiting workers from being positioned directly below active work - workers at lower levels must be offset horizontally within shaft space or excluded from shaft during overhead work creating dropped object risk. For complex multi-step operations such as installing and joining multi-section riser assemblies, develop job-specific work procedures documenting step-by-step sequence, required communication at each step, designated worker positions at each level, and verification requirements before proceeding to next step. Conduct pre-start meetings each day involving all workers participating in riser work reviewing day's work plan, communication protocols, specific hazards anticipated, and emergency procedures. Where shaft configuration allows, install visual communication aids such as shaft cameras allowing workers to verify others' positions, colored lights signaling ready status at different levels, or mirrors positioned allowing line-of-sight through shaft openings. Establish backup communication for radio failure situations using agreed physical signals such as whistle codes, tapping signals transmitted through pipes, or light signals visible between levels, with procedure to cease work if primary communication capability is lost until restored or backup method verified functional. For emergency situations, establish emergency signals understood by all workers such as continuous whistle blast or repeated "EMERGENCY" radio calls requiring immediate work cessation and implementation of emergency procedures. Brief workers on prohibition of solo work in multi-level installations requiring minimum two workers maintaining communication capability and emergency response capacity. Implement supervisor verification checking communication protocols are being followed through random observations of work and immediate correction if shortcuts or informal methods are observed. Document near-miss incidents where communication failures nearly resulted in incidents conducting formal lessons-learned analysis identifying root causes such as unclear communication, misunderstood signals, inadequate radio discipline, or assumption rather than verification, implementing corrective actions such as revised communication protocols, additional worker briefing, or enhanced supervision. Consider communication training for workers unfamiliar with radio use covering radio discipline (clear concise messages, proper procedure words, prohibition of casual conversation on work channels), signal protocols (standard phrases used consistently), and emergency communications. For particularly complex installations or high-risk operations, designate communication coordinator responsible for coordinating multi-level activities, ensuring all workers are aware of work plan, verifying readiness before activities commence, and monitoring for communication failures or coordination problems. Test communication systems before work begins each day verifying radios function throughout shaft depth, all workers understand signals, and backup methods are known. Remember that communication failures in multi-level work have caused serious incidents including workers crushed by pipes released unexpectedly from above, struck by dropped objects, or injured when receiving worker was not positioned properly because sending worker proceeded without confirmation - rigorous consistent communication discipline prevents these incidents making communication protocols not bureaucratic procedure but essential safety system.

Mechanical lifting systems for vertical pipe movement in riser shafts provide substantial safety and efficiency benefits compared to manual lifting which creates extreme musculoskeletal strain in confined vertical spaces. System selection depends on building height, shaft configuration, pipe weight, and project duration. For low-rise installations up to 4-5 floors, portable rope and pulley systems provide practical solution using mechanical advantage reducing manual force required - typical 3:1 or 4:1 pulley systems allow one or two workers to raise pipes that would otherwise require 3-4 workers for manual lifting. Install temporary pulley assemblies at top of shaft secured to structural elements capable of supporting full pipe weight plus dynamic loads, with rope extending to ground level or working floor. Workers at base attach pipe to rope using secure sling, workers at top haul rope raising pipe with workers at intermediate levels guiding pipe preventing binding against shaft walls or structures. For medium-rise installations 5-10 floors, portable winches or hand-operated lever hoists provide greater mechanical advantage positioned at strategic floors - typically install winch at top floor or at intermediate floor aligned with shaft allowing controlled raising or lowering of pipes. Electric winches provide easier operation than manual winches for repetitive lifting but require electrical supply in shaft. Winch capacity must exceed maximum pipe section weight - typical plumbing riser pipe sections weigh 20-50kg requiring winch capacity 100-200kg accounting for safety factor. For tall buildings exceeding 10 floors or large-diameter heavy steel risers, purpose-built pipe installation equipment provides most efficient solution - some mechanical contractors use specialized riser installation rigs comprising powered winches with remote controls, guide systems maintaining pipe alignment during lifting, and automated feed systems. For external building risers accessible to cranes, crane lifting of pre-fabricated multi-floor riser sections provides maximum efficiency - fabricate complete riser sections at ground level including all joints, branches, and fittings, crane-lift complete assembly positioning at multiple floors simultaneously secured at each floor as lifting progresses. This approach minimizes work in confined shafts and reduces total installation time substantially. Lifting equipment safety requirements include securing lifting equipment to structural elements verified capable of supporting loads with appropriate safety factors (typically 5:1 for static loads), using certified lifting equipment with current inspection and load rating tags, implementing fall protection preventing workers falling down shaft while operating lifting equipment positioned near penetrations, establishing dropped object prevention ensuring pipes remain secured during lifting and tools cannot fall if dropped, providing worker training in lifting equipment operation including load limits, proper rigging techniques, and emergency procedures if equipment fails or pipe becomes jammed. For all mechanical lifting systems, implement systematic communication protocols between workers at different levels using two-way radios with standard signals before, during, and after each lift. Never rely on shouted voice communication between floor levels as this is unreliable and easily misunderstood. Consider pre-fabrication opportunities reducing number of individual lifts and amount of jointing work in confined shafts - joining multiple pipe sections at ground level or at convenient floor levels creating longer assemblies reduces total lifts required and associated manual handling. Brief workers that mechanical aids are mandatory for pipe lifting with manual lifting only permitted for light pipes (typically under 15kg) that one worker can safely control - never manually lift heavy pipes simply because mechanical equipment setup takes time, as this creates serious injury risk. Maintain lifting equipment throughout installation period with daily pre-use inspections checking wire ropes for damage, pulley wheels rotate freely, winch brakes function correctly, and securing points remain tight. Document lifting operations particularly for heavy or complex lifts with lift plans showing rigging arrangement, load weight, equipment capacity verification, and worker positions providing reference for similar future lifts. Remember that manual handling injuries dominate plumbing injury statistics with back injuries often causing permanent reduced work capacity - investment in mechanical lifting equipment provides both immediate project safety benefits and long-term worker health protection supporting sustainable plumbing careers rather than injuries forcing early retirement from physical inability to continue trade work.