formwork guide

8/22/2019 Formwork Guide

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INDUSTRY GUIDE

FOR FORMWORK

CONSTRUCTION INDUSTRY SOUTh AUSTRAlIA

JUNE 2012


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1

INDUSTRY GUIDE

FOR FORMWORK


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Awdt

This guidance material has been developed by a tri-partite industry

working party and has involved extensive consultation with industry

and other special interest groups. The contribution of the following

organisations is acknowledged:

BuiltEnvironsPtyLtd

Construction,Forestry,MiningandEnergyUnion

HansenYunckenPtyLtd

HindmarshAustralia

MitconFormworkPtyLtd

NewgenFormworkers

SystemFormworkPtyLtd

SafeWorkSA

Diaa t :

BovisLendLease

WorkplaceHealthandSafetyQueensland

SafeWorkSA

Phtaph t :

Construction,Forestry,MiningandEnergyUnion

MitconFormworkPtyLtd

SystemFormworkPtyLtd

HindmarshAustralia

Diai

Information provided in this publication has been prepared by industry

representatives and is designed to prevent injury to anyone engaged in

erecting and dismantling formwork and associated equipment.

This publication is correct at the time of printing and is provided as general

information only. In utilising general information about workplace health

andsafety,thespecicissuesrelevanttoyourworkplaceshouldalwaysbe

considered.

Theremaybeadditionalrisksataworkplacethathavenotbeenspecically

addressedinthisguidance.UndertheSouthAustralianoccupational

healthandsafetylaws,suchrisksmustbeidentiedandcontrolmeasures

implemented and reviewed to eliminate or minimise exposure to these risks.

Usersofthisguidancematerialshouldbeawarethatitisbasedoncurrent

knowledge and construction methods within the industry and is not intended

to exclude other methods or processes that can also meet the required

safetystandards.Thisindustryguide,onanyparticularaspectoflegislation,

is not to be taken as a statement of law. To ensure compliance with your

legalobligationsyoumustrefertotherelevantActs,Regulationsand

ApprovedCodesofPractice.Thispublicationmayrefertolegislationthathasbeenamendedorrepealed.Whenreadingthispublicationyoushouldalways

refer to the latest laws.

PrefAce

ThisIndustryGuideforFormworkisbasedontheSouth

AustralianOccupational Health, Saety and Welare

Regulations 2010.GiventhatSouthAustraliaislikelytoadopttheharmonisedlegislation,itisrecommended

that readers of this document also become familiar with

therequirementsoftheWorkHealthandSafety(WHS)

legislation once it comes into effect.

SafeWorkSA,incollaborationwithmembersofthe

ConstructionIndustry,hasproducedthisguidanceto

provideemployers,self-employed,andemployeeswith

practical advice on preventing injury to anyone engaged

in erecting and dismantling formwork and associatedequipment.

AspartoftheSAConstructionIndustryOHSCommittees

strategytoaddressareasofhighrisk,itwasagreed

that the creation of appropriate industry guidelines for

erecting and dismantling formwork and associated

equipment was a priority.

It was further agreed that the codes of practice and

guidelines,existinginotherstates(Queensland,NewSouthWalesandVictoria)andoperatingeffectively,could

be utilised in the development of a similar resource for

SouthAustralia.

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conTenTs

1. Itdti 4

1.1 Fallsfromheightlimitationsofharness 4

systems for formwork activity

2. Di 5

2.1 Safedesignofbuildingsinrelat iontoformwork 5

2.1.1 Buildability 5

2.1.2Materials 5

2.2 Formworksystems 6

2.2.1 Safeformworkdesignandverication 6

2.2.2Formworkdesigncerticationrequirements 6

2.2.3 Documentation 7

2.2.4 Designvariations 8

2.2.5 On-sitecoordinationandverication 83. cdiati ad adiitati 9

3.1 Workprogram 9

3.2 Housekeepingaccessandstorage 9

3.2.1 Accessandegress 9

3.2.2Materialstorage 9

3.2.3 Rubbishstorageandremoval 9

3.2.4 Storagetominimisemanualtaskrisks 9

3.3 Training 10

4. W t 10

4.1 Formworkerectiontraditionalsystems 10 4.1.1 Foundations 11

4.1.2 Falsedeck 11

4.1.3 Erectingframes 11

4.1.4 Installingbearers 12

4.1.5 Installingjoists 12

4.1.6 Fallprotectionfromtheformworkdeck 12

4.1.7 Edgeprotectionontheformworkdeck 13

4.1.7.1 Formworkconstructionzonephysicalbarriers 13

4.1.7.2 Edgeprotectiononcompleteddecks 13

4.1.8 Layingaformworkdeck 13

4.1.8.1 Gettingstartedsafeaccess 13

4.1.8.2 Typicalworksystemforaleadingedge 15

4.1.8.3 Layingaformplydeck 15

4.1.8.4 Layingametaldeck 16

4.1.9 Cantileverrequirements 16

4.1.10 Penetrations 16

4.1.11 Workingzonesforformworkersandothers 17

4.1.12 Changingoorlevels 18

4.2 Formworkerectionmodularformworksystems 18

4.2.1 Basicmodularsystems 18

4.2.2 Training 18

4.3 Strippingformwork 18

4.3.1 Generalformworkstripping 18

4.3.2 Safeworkmethodstatements 18

4.3.3 Certicationpriortostripping 19

4.3.4 Exclusionzone 19

4.3.5 Dropstripping 19

4.3.6 Bondreduction 19

4.4 Craneandotherloadhandlingsystems 19

4.4.1Loadingmaterialsduringformworkconstruction 19

4.4.2 Slingingloads 19

4.4.3 Liftinggear 20

4.4.4 Liftingformworkmaterials 20

4.4.5 Liftinglugs 20

4.5 Useofladders 20

5. spia qit wa ad 21

5.1 Bracingforwindloading 21

5.2 Accessplatforms 21

5.3 Liftingmethods 21

6. spia qit ip ad p 22

6.1 Accessandegress 22

6.2 Workplatforms 23

6.3 Trailingscreensandplatforms 23

6.4 Climbingtheform 23

6.5 Training 24

6.6 Healthissuesandamenities 24

6.7 Engineeringissues 24

6.8 Emergencyissues 25

7. fai t 26

7.1 Hazardcontrols 26

7.2 Preventtheobjectfromfalling 26

7.3 Perimetercontainmentscreens 26

7.3.1 Screenheightatbuildingstep-ins 26

7.3.2 Perimeterscreengaps 27

8. Hath 27

8.1 Noise 27

8.2 Dustandatmosphericcontaminants 28

8.3 Manualtasks 28

APPenDIces 29

Appendix1:Denitions 29

Appdix 2: Taii 30

Appendix3:Sampleengineerscerticationletters 31

Appdix 4: ctti hit 33

Appendix5:Samplestructural(pre-pour)certicate 34

Appdix 6: Dt d i 35

w t


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1. Itdti

Formworkisthesurface,supportsandframingusedtodenethe

shapeofconcreteuntiltheconcreteisself-supporting(seeAS 3610-

1995 Formwork or Concrete).

Forthepurposesofthisguide,theformworkassemblyincludes:

theformsonwhichconcreteispoured

thesupportstowithstandtheloadsimposedbytheforms

and concrete

anybracingaddedtoensurestability.

Hazardsassociatedwiththeerection,alterationordismantlingof

formwork include:

fallsfromheight

fallingobjects

formworkcollapse(before,duringandafterpouringofconcrete)

slipsandtrips

noise

dust

manualtasks

sharpedgesonmetaldecks

sunglare.

Toproperlymanagerisks,apersonmust:

identifyhazards

assessrisksthatmayresultbecauseofthehazards decideoncontrolmeasurestoprevent,orminimise,

the level of risk

implementthecontrolmeasures

monitorandreviewtheeffectivenessofthosemeasures.

Controlmeasuresmustbeimplementedinanorderofpriorityand

beforeworkcommences.Figure1belowillustratesthehierarchy

of controls which represents the order of priority for controls where

there is a risk that a person could fall.

1.1 fAlls from HeIgHT lImITATIons of HArness

sysTems for formWork AcTIvITy

Whenerecting,alteringordismantlingformwork,theuseofthe

following systems is not recommended:

travelrestraintharnesssystemstopreventafall fallarrestharnesssystemstoarrestafall.

Travel restraint harness systems are impractical for formwork as:

thecontouroftheleadingedgeisconstantlychanging,requiring

the length of the travel restraint line to be continually adjusted

multiplelanyardanchoragepointsmayberequired

thegreaterthenumberofworkersbuildingtheformworkdeck,

the greater the likelihood of lines becoming tangled.

Fall arrest systemsareprohibitedundertheSouthAustralian

Occupational Health, Saety and Welare Regulations 2010(OHSWRegulations)insituationswherethereisinsufcientdistance

availabletopreventapersonhittinganobject,thegroundoranother

surface,otherthanaverticalsurface.Forexample:

Whenerecting,alteringordismantlingformwork,theremaybe

insufcientfreefalldistanceunderneaththeworkingarea,

resultinginafallingpersonstrikingtheground,aframeorother

obstruction prior to the fall being arrested.

Afallingpersonmayrequireafreefalldistanceinexcessof

6mforthefalltobesafelyarrestedbyaharnesssystem.In

somesituations,thisdistancecanbesubstantiallyreducedbythe use of shorter lanyards and/or higher anchorage points.

Theanchoragepointdesignloadrequiredforfallarrestsystems

isrelativelyhigh.TheOHSWRegulationsspecifythateach

anchorage point of the system must have a minimum capacity of

15kNforonepersonfree-falling.

Theerectionofformworkframesusingfallarrestharnesses

requires the user to regularly disconnect from and reconnect to

anchoragepoints,requiringtheuseofadoublelanyard.

Figure 1 Hierarchy o controls Controlling the risk o alls

Di ad pai

Eliminatetherisk

during the design and

planning stage.

Wh thi i t patia,

1 t:

Workonasolidconstructionwithsafeaccess/egress,edgeprotection,openingscoveredetc.

Wh thi i t patia,

2 t:

Usefallpreventionsystemse.g.temporaryworkplatforms,scaffolds,perimeterguardrails,elevating work platforms.

Wh thi i t patia, 3,

thenlevel4ornally,level5controls:

l 3useworkpositioningsystems,

travel restraint systems

l 4usefallarrestorcatchplatformsl 5useladdersoradministrationcontrolse.g.nogoareas,permitsystems,safe work systems.


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cid th wi i a ha t:

Ariskassessmentaddressingthehierarchyofcontrolsshouldbe

usedtoidentifysatisfactoryalternativestoaharnessbasedon

fall prevention measures.

Implementingtheuseofsolidworkzonebarriersisone

effectiveengineeringsolution.Refertosection4.1.7ofthisguide

for further information.

Trainingisrequiredbeforeapersonusesaharness.Fortraining

requirementsundertheSouthAustralianOccupational Health,

Saety and Welare Act 1986(OHSWAct),pleasereferto

Appendix2.

2. Di

Undersection23aDutiesofdesignersandownersofbuildingsoftheOHSWAct,designersofbuildingstobeusedasworkplaceshave

obligations for workplace health and safety.

2.1 sAfe DesIgn of buIlDIngs In relATIon To formWork

2.1.1 bidaiit

Buildingdesigners,includingengineersandarchitects,must

considerthebuildabilityofastructureorbuildingwiththeobjective

of producing a design that minimises the risk of injury during

construction.

Thedesignofthenalconcretestructuremayhaveamajoreffectontheeaseofformworkconstructionandconsequently,onthesafetyof

peopleduringconstruction.Generally,amorebasicandsimplenal

concrete structure is safer to erect.

Aformworkdesignershouldbeconsultedduringthedesignofany

building to provide input on ways to minimise the risk of injury arising

from formwork activities.

The following design measures could be considered to minimise

exposure to risk of injury during the construction of formwork:

Reducevariationsintheoordepthi.e.constructaoorsothat it has one consistent depth. Decks that are a consistent

depthareeasiertoerectthanvariabledepthoorsandreduce

theriskofinjury.Deeperbeamsintroducedropdownsinto

theoor,creatingtripandfallhazards,andrequiremoreworkto

construct and strip after pouring.

Wherebeamformsareessential,lightweighttemporaryaccess

across the beam recess must be provided to prevent injury to

workersfromsteppingintotheformduringconstruction(see

Figure2above).

Reducethenumberofcolumnsrequiredandwherecolumnsdo

exist,eliminatecapitalsanddropdowns.

Utiliseprecastcolumnsandbeams.Thiscanreducetherisks

associatedwithxingreinforcement,erectingandstripping

columnformworkandpouringconcreteon-site.Workactivities

carried out in a factory environment are generally lower risk.

Reducecantileveredoorsections.

Planformanualtasks.Considerationshouldbegiventothe

suitability of the design of different formwork systems that willreduce manual handling risks such as:

- table forms

- systems with lighter weights of materials to be handled

- methodsofformworkerection,alterationanddismantling

- improved access and egress for workers and movement

of materials and equipment

- methodsformovinglargeandheavycomponents,materials

and equipment i.e. making allowances for a crane and other

mechanical lifting devices to be used.

2.1.2 matia

Allmaterialsandequipmentusedinformworkconstructionmust

betfortheintendedpurpose,meetdesignspecicationsandbe

designedtoconformtorelevantAustralianStandards.Equipment

must be manufactured in accordance with a quality assurance

systemthatensurescompliancewiththedesignspecication.

Evidenceverifyingthatformplysheetsandtimberbearersconform

toAustralianStandardsshouldbekepton-site.Suchevidencemay

include:

apurchaseorderwhichdetailsthespecicationsofthe

form ply sheets ordered

formplysheetsbeingmarkedinaccordancewithAustralian

Standards(seeAS/NZS 2269.0:2008 Plywood-Structural-

Specifcation).

Figure 2 Flat oor and temporary access as

all protection or deep oor beams


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Ifalternativeproducts,otherthantimberareused,anengineer

should verify that they are adequate for purpose.

2.2 formWork sysTems

InAustralia,formworksystemsaregenerallydesignedto:

AS 3610 Formwork or Concrete

AS 3600 2009 Concrete Structures.

2.2.1 Safeformworkdesignandverication

Adesignerofformwork,eitheraformworkdesigneroranengineer

(seeAppendix1fordenitions),isresponsibleforoverseeingthe

safe design of the complete formwork structure. This includes

designoftheformworksupportstructure,theformworkdeckand

connection details.

Whenspecifyingthedesignoftheformworksystem,aformworkdesigner must allow for all expected loads applied during the three

phasesofconstructioni.e.duringformworkerection,duringconcrete

pouring and after concrete pouring is complete until the structure is

self-supporting. This includes loads applied by:

theformworkdeck,supportingmembersandformworkframes

anyfalsedecksthatmaybeprovided

concretepouringtechniques(i.e.concreteskiporpump)

theconcretepour,whichincludesboththeweightofthe

concreteanddynamicfactorsapplied,includingtheconcrete

pour rate and pour sequence workersontheformworkdeckandfalsedecks

stackedmaterials

crane-liftedmaterialsonboththecompleteandincomplete

formwork deck

environmentalloads,includingforcesduetowaterowing

aroundtheformwork.Rainandrunoffcanhaveadetrimental

effect if not considered by a designer

wind,asdetailedinAS 1170.2:2011 Structural Design Actions

Wind Actions:

wind loading will vary depending on:

- thesizeofform

- the nature of the form

- wind speed

- windresistance(e.g.screens)

- wind direction

windloadingonverticalforms,particularlyforexternalwalls,

columns,freestandingshutters,bladewallsandany

platforms that may be subject to uplift

vertical elements should be fully braced prior to and during

stripping until such time as the construction provides

adequate support against wind loading shadeclothusedonscreens,signageandoutsidescreens

will increase the effective wind loading of an open structure

the geographical location of the construction site will have a

bearingontheseverityofwindonthestructure.Wind

generally has less effect in built up or hilly areas

AS 1170.2 Structural Design Actions Wind Actions

speciesfourdifferentterraincategoriesthatshouldbe

taken into consideration by a formwork designer as well asbasicwindspeedsfordifferentzonesinAustralia

[practicallyallareasofSouthAustraliafallunderRegionA

(normal)].

Refertosection4StructuralDesignandDocumentationof

AS 3610 Formwork or Concretefor further details on formwork load

calculations.

2.2.2 Formworkdesigncerticationrequirements

This guide considers two types of formwork systems: ai and-ai.Aformworkdesignermaycertifyabasicformwork

system,whereasonlyanengineermaycertifyanon-basicformwork

system.

Whilethisguiderecommendsthatonlyanengineermaycertifya

non-basicformworksystem,itisrecognisedthatacompetentperson

experiencedinformworkdesignanddocumentation,suchasa

formworkdesigner,mayperformthemajorityofthedesignwork.

Forbothbasicandnon-basicformworksystems,certicationshould

conrmthattheformworkmeetstherequirementsofAS 3610

1995 Formwork or Concreteand the construction drawings. Thiscerticationshouldalsoconrmthatotherformworkandproject

documentationdetailedinsections2.2.3ofthisguide,havebeen

completedasrequiredfortheproject.Sampleengineerscertication

lettersareprovidedinAppendix3.

bai w t

Forthepurposesofthisguide,abasicformworksystemisthe

formworkforaoor,wallorcolumnandincludes:

standardformworkframeswhichhaveaknowntestedloading

capacity and are spaced at no more than the recommended

distancesapartforanormaloorthicknesswithbearers,joists

and form board on top of them

speciallymanufacturedanddesignedformworksystemswith

proprietary formwork components and rated load calculations in

linewiththemanufacturersspecications.

Abasicformworksystemislimitedbythefollowingconditions:

theheightoftheformworkmaybeuptoamaximumof6mto

thesoftofthenewoorfromthesupportingoor

wallsandcolumnsmaynotbegreaterthan6mfreestanding fromtheooronwhichtheformworkwillbesupportedtothetop

surface of the concrete

anyback-proppingisexcludedfrombasicformworksystemsand

istobecertiedbyanengineer.


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Eitheraformworkdesignerorengineermaycertifyabasicformwork

system.Whereanyoftheseconditionsareexceededorback-

proppingisinvolved,thesystemistobeclassiedasanon-basic

formworksystemandmustbecertiedbyanengineer.

n-ai w t

Formworksystemsthatexceedthedescriptionofabasicformwork

systemare,forthepurposesofthisguide,categorisedasnon-basic

formworksystems.Forthepurposesofthisguide,onlyanengineer

may certify:

thedesignofanytemporaryorpermanentformworkstructures

categorised as non-basic formwork systems

anyback-proppingusedforeitherbasicornon-basic

formwork systems.

Non-basicformworksystemsincludeformworkstructuresforany

oor,wallorcolumnhigherthan6m,orthreeframes,orthreetimesthe least base width of the scaffold.

2.2.3 Dtati

The extent of documentation required for any structure may vary

depending on the complexity of the formwork and supporting

structure design and the conditions in which it is to be constructed.

The documentation requirements outlined below are provided as

aguideonly,forsituationswherethereisacomplexconstruction

processatheight,thatisconsideredtobehighrisk.Itisexpected

that some elements of documentation may be reduced or omitted forsome more basic and lower risk construction applications.

fw dawi

Formworkdrawingsexplainthegeneralarrangementoftheformwork

plans,elevationsandsections,identifyingandlocatingallmembers

and components including bracing.

Anengineershouldnominatethefollowingonthedrawingsorother

documentation:

maximumallowablepointloadingtobeappliedandany additionalproppingrequirementsatanyspecicloadingarea

componenttypesandspacing

maximumjackextensions

bearerandjoisttimbertype,dimensionsandspacing

propsizesandmaximumextensions

methodsfortyingthestructuretogetherandspacingbetween

ties(ifrequired)

formplysize,thicknessandgrade.

WhereeccentricloadingistobeappliedtoU-heads(i.e.single

bearersarepositionedtoonesideoftheU-head),theformworkdrawings must state that this is permitted.

oth w dtati

The following information should be included in the formwork

documentation:

anynecessarypreparationofthefoundationsuchaslling,

compaction and drainage anyfootingdesignassumptions,suchasfoundationmaterial

description,safebearingvalues,limitationsonsettlementduring

erectionofformwork,placementofconcreteanddismantlingof

formwork.Referencetoinformationsourcessuchas

geotechnical reports may also be included

footingdetails,suchastypeandsizeoffootings,levelofsoft,

concretemixdesignstrength,reinforcement,specication

anddetailsofsitellingorcompaction,andprecautionsagainst

washouts

sufcientdetailstofullydescribeimportantorunusualfeatures

oftheformworksystemdesign,includingdesignassumptions,

particularlythoserelatingtostrength,stabilityandstiffness

theareasoftheformsdesignedtocarrystackedloads,together

withthemaximumallowableload,andtheminimumstrengthof

concrete to be achieved prior to materials being stacked

Safeworkmethodstatementsaddressing:

the erection and stripping of the formwork assembly

methods for securing single or multiple props

methodsforeldadjustmentoftheformspriortoand

during concrete placement

verticalpourratesinmetresriseperhour,includingtherisksand implications of exceeding vertical pour rates

sequenceofconcreteplacement,includingdirectionof

intendedpouronrakingorslopingsurfaces(e.g.carpark

ramps and minimum elapsed time between adjacent

placements)

wrecking strips and other details relating to stripping of

the forms

certicationofnon-proprietaryequipment

referencetodocumentationforproprietaryitems

whererequired,locationofweepholes,vibratorholes,clean-out

holes and inspection openings acceptancecriteriaforsingleuseformwork.

Pt dtati

Otherprojectdocumentationshouldincludethefollowing

information:

detailsoffallandedgeprotectioni.e.perimeterscaffolding

locationofanymandatoryjointsandanyspecialproceduresfor

locating other joints

detailsofanyinserts,waterstops,speciallyformedshapesor penetrationstobeconstructed,thelocationanddetailsofwhich

are critical to the serviceability of the permanent structure

informationonanyarchitecturalorstructuralcomponentdetails

to be cast into the structural concrete


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detailsofthecamberingofanyslabsorbeams

informationaboutanypermanentformworksystems,together

withlimitationsondeectionsandanyspecialrequirementsfor

their erection and concreting

limitationsontheuseofthepermanentstructurefortherestraint

of formwork minimumstrippingstrengthortimes,strippingproceduresand

requirements for health and safety

detailedinformationontheeffectofpreorpost-tensioning

procedures on the formwork and any special procedures to be

adopted in the stripping of formwork

detailsofback-proppingthatmayberequiredandminimum

timeintervalsbetweenconcretepours,includingrequirements

for propping of any composite construction

requirementsfortheminimumnumberoflevelsofsupports

relativetothetypeofformwork,thetimingandsequenceof

oorpropping,andtheanticipatedtimebetweenconstructionof

subsequentoorsformultistoreystructures.

2.2.4 Di vaiati

Allformworksystemdesignvariationsmustbecheckedbyaformwork

designerforabasicsystem,oranengineerforanon-basicsystem.

Thevariationsmustbecertied(inwriting)ascomplyingwith

AS 3610 Formwork for Concreteor whether they need to be altered

in accordance with written directions to comply withAS 3610.

Potentialvariationsmayinclude:

thenumberofformworkframesundertheformworkdeck

typesandnumberofbracesorpropsotherthanindicatedon

the formwork drawing

typesand/orquantitiesoftiesontheformworkstructure

spansonmemberssupportingtheformworkdeck

back-proppingsystemsspeciedbyanengineer

connectionsbetweentraditionalformworkand

modular formwork.

2.2.5 On-sitecoordinationandverication

Complexprojectsrequireconstantandvigilantcoordinationbyan

experiencedmanagementandsupervisoryteam.Withproperly

scheduledandcoordinatedactivities,sub-contractorsareabletocarry

outtheworkinanorderly,safe,andmoreproductiveway.

Effectivecoordinationandtechnicalaccuracyalsorequirethat

formwork,projectandvariationdocumentationarereadilyaccessible

on-site.

Wheneffectivesitecoordinationisnotimplementedoraconstruction

teamdoesnothaveaccesstoessentialtechnicalinformation,the

potential for failure increases.

Vericationoftheformworkstructure

Aneffectivequalitycontrolsystemmustbeimplementedforthe

construction of formwork. The system should ensure that:

materialsandcomponentsusedon-sitecomplywiththeformwork

designspecications,drawingsanddocumentation

damagedorexcessivelywornmaterialsandcomponentsarenot

used,butareidentiedandsentoff-siteforrepairoraredestroyed.

Theformworkstructurescompliancewithitsdesignmustbeveried

anddocumented.Aconstructionchecklistmaybeusedasaguidefor

thisprocess(refertoAppendix4forasamplechecklist).However,

relying solely on a checklist does not necessarily verify compliance with

relevantAustralianStandards.

Thedesignvericationanddocumentationprocessmaybedelegated

toacompetentpersonwho,ifnotanengineerorformworkdesigner,

musthavetheexperience,trainingandknowledgetoperformon-site

inspectionsoftheformworksystem(refertoAppendix1fordenitions).

The competent person must be:

experiencedinformworkconstruction

competentininterpretingdrawings

abletocertifythattheformworkstructuresatisesthedetails

ontheformworkdrawings,specicationsandanyotherformwork

documentation.

Shouldthecompetentpersonon-sitenotbeaformworkdesigneroran

engineer,thecompetentperson:

mayonlyverifythattheformworkstructurecomplieswiththe

designersspecicationsanddrawings

maynotauthorisevariationstothedesign mustprovideanyconstructionchecklistreferralstoanengineer

in writing

mustprovidewritteninstructionstotheformworksupervisorfor

any remedial actions that need to made to the formwork system

prior to the concrete pour

mustensurethatanyremedialactionrequiredhasoccurredprior

totheconcretepour,includinganyitemsreferredtoanengineer.

Pre-pourinspectionmustfocusonsuchmattersas:

thelatestversionofstructuralandformworkarrangement

drawings and details submitted

correctspacingofframes,propsandtimbers

correctjoistandbearersizes,andloading

acceptablejackextensions

adequatebracingtoensurestability.

Pre-pourinspectionsarethelastreasonableopportunitytoensure

compliancewiththeformworkdesignspecications.Suchinspection

records form an important part of the site quality control system and

mustbesigned-offbyanengineer,formworkdesignerorcompetent

personfollowingthenalpre-pourinspection.Asamplepre-pour

structuralinspectioncerticateisprovidedatAppendix5.

c dt i w yt

Appendix6illustratessomeofthemorecommondefectsthat

are likely to occur in a formwork system. The list is intended to


10/379

give guidance to a competent person and is not considered to be

exhaustive.Inanyindividualcase,theimportanceofitemsmayvary

and only a competent person can assess their relative importance.

3. cdiati ad adiitati

3.1 Work ProgrAm

Therisktoapersonshealthandsafetymustbeconsideredwhen

designingaworkprogramforerecting,alteringordismantling

formwork.Considerationshouldbegivento:

edgeprotectionrequirementsandensuringthesearedesigned

and constructed in a timely manner to be safe to use

sequencingworktoensurethatsufcienttimeandresources

are allowed for each work activity

coordinatingtradestoallowworktobecompletedfreefrom

obstruction.

3.2 HousekeePIng Access AnD sTorAge

Formworkconstructionresultsinaconstantlychangingwork

environment,withrestrictedaccessthroughframesandformwork

supports,oftenwithlargevolumesofmaterialandwaste.Forthis

reason,itrequiresongoingmonitoringofhousekeepingpracticesto

maintain a safe and productive workplace.

Include housekeeping as an essential aspect of every job whether

itbethroughworkinstructions,regularinspectionoftheworkplace,or site/task induction training. Instructions should include time and

resources for the progressive clean up of work areas to prevent

rubbishandredundantmaterialsfrombecomingatriphazardandto

allow safe access for mechanical aids.

3.2.1 A ad

TheOHSWRegulationsrequirethattherebeclearaccessto

andfromtheworkplaceinaccordancewithDivision1Access

and egress.

Clearaccessisimportantforthesafemovementofmaterials,

equipment and anyone on-site. Designated access ways should be

providedandanyoneon-siteshouldbedirectedtousethem.Access

waysmustbekeptclearofanyrubbish,plantormaterials.

Insomesituations,greenhazardtaping/buntingorothervisual

methods can clearly show where access ways are located. This

is particularly important where access is required through

formwork frames.

Emergencyaccessandegressmustbeprovidedtoallpartsofthe

workplace. The following situations should be considered:

stretcheraccessandegress

peoplecarryingtoolsandequipment

useofstairs

provisionoftwomeansofegressatalltimes.

3.2.2 matia ta

TheOHSWRegulationsrequiresafestackingandstorageofplant

andmaterialsataworkplace,asdetailedinDivision15Storage.

Materialsmustbestoredinawaythatminimisesmanualtask

hazards,triphazardsandthepotentialforhazardsfromfallingobjects.SmallercomponentssuchasU-heads,couplers,baseplates

andZ-barsshouldbestoredinlabelledmaterialboxes,markedwith

safeloadlimits(SLL).

Wherepracticable,frames,formplysheets,bearersandjoists

should be strapped in bundles or stacks and be located away from

theedgeofthedeck,topreventmaterialsoranyoneaccessingthem

from falling.

Wallformsshouldbestackedinsuchawaythattheycannotslide,

orrotateawayfromthesurfacetheyareplacedagainst.Anengineer

shouldverify,inwriting,thatasurfacetobeusedforstackingforms

iscapableofwithstandingtheimpactofallimposedloads,including

windloading.Ifpurpose-madeA-framesarenotavailablefor

storingwallformswhennotinuse,itispreferabletolaythemat

ontheground,ratherthanleaningthemagainstotherstructures.

Timbers,orothereffectivemeansofsupport,shouldbeusedunder

forms where slings are to be used for lifting.

3.2.3 rih ta ad a

Rubbishstorageandremovalforformworkmayincludethe

provision of rubbish skips and wheelbarrows that are moved as work

progresses.However,rubbishskipsmayonlybepositionedwhere

the supporting structure has adequate strength to support the total

weight of the bin and its likely contents.

3.2.4 sta t iii aa ta i

Incorrect material delivery and storage practices can create

signicantmanualhandlingrisks.Safeworkpracticesthatcanassist

in minimising these risks include:

ensuringthatformworkmaterialsaredeliveredascloseas

practicable to the job

designinganddesignatingasmallsectionoftheformworkdeck

as a loading platform for ply and other components

ensuringmechanicalaidsareusedtohandleloadswherever

possible

storingloadsontrolleystominimisedoublehandling,oron

raised platforms to minimise manual lifting from ground level

havinganadequatestoragespaceorlaydownareastosafely

store materials/equipment and to minimise double handling.


11/3710

3.3 TrAInIng

Anyonewhomaybeexposedtoworkplacehealthandsafety

risks resulting from formwork construction must be provided with

informationandtrainingthatisspecictotheformworksystemthat

is being used. Training and information should include details of:

theformworksystem,components,tasksandactivities

thewaythemanufacturerordesigneroftheformworksystem

intendedittobeerected,installed,used,moved,alteredor

dismantled

therangeofhazardsassociatedwiththeformworksystem,

controlmeasurestominimiseexposuretotherisks,thecorrect

use of controls and how to ensure controls are maintained

anyspecialrequirementstoundertakeorparticipateinspecic

tasks or activities

anysafeworkmethodstatements,includingtheuseofmechanical aids and devices

theuseandmaintenanceofequipment,includinganyspecic

conditionsandprohibitionsonitsuse.Wherenecessary,

referenceshouldbemadetooperatorsmanuals

anyspecialsafetyinformationneeded,suchassafety

precautions for working under certain conditions including hot

workorconnedspacework

personalprotectiveequipmentrequirements,including

instructionsfortting,use,cleaning,maintenanceandstorage

theavailabilityandcontentofthisindustryguidancedocument.

FortrainingdetailsrefertoAppendix2.

4. W t

4.1 formWork erecTIon TrADITIonAl sysTems

TheOHSWRegulationsdescribewhatmustbedonewherethere

isariskapersoncouldfallinDivision13PreventionofFalls.

Thelegislationalsorequiresthatahazardidenticationandrisk

assessmentbeconductedand,wherenecessary,safeworkmethod

statements documented.

Formworkactivitiesmustcomplywithregulatoryrequirements

fortheerectionofscaffolding.Formwork,likescaffolding,mustbe

erectedsafelyandsystematically,andbetiedinprogressivelyto

stabilise the structure.

Apersonmustbeprovidedwithaworkingplatformatleast

450mmwide(i.e.twoplanks)evenwhenthepotentialfalldistance

is less than 2 m. It is not acceptable for a person to work from a

single plank or bearer.

Irrespectiveofwhichframingsystemisused,workersmustalways

use working platforms that are two planks wide as a minimum.

Whereapersonistoinstalljoists,thiscanbeachievedusingatwo-

plankworkplatformfromunderneath,allowingtheverticaldistance

between the formwork deck and the false deck to be increased. This

isillustratedinFigure3below.

Figure 3 Worker erecting ormwork on two planks

>2.0

vArIAble


12/3711

4.1.1 fdati

Formworkmustbeerectedonastablebasetopreventtherisk

ofcollapse.Suspendedslabsmustbeabletosafelysupportloads

thatmaybeappliedbytheconcretepour,workersandcrane-lifted

loads etc.

Baseplatesmustbeprovidedunderpropsandstandardson

formworkframesunlesstheproporstandardhasanintegralfoot,or

an engineer documents that a base plate is unnecessary.

Soleboardsdesignedtosuitthegroundconditionsmustalsobe

usedunderpropsandstandardsonnaturalground,unlessan

engineerstatesotherwise.Framesandpropsmustbelocatedon

asoundbasethatwillnotsubside,failorwashaway.Theprincipal

contractor is responsible for providing all information on ground

conditions to the engineer or formwork designer.

4.1.2 fa d

In situations where a deck is being installed at a height that would

require a person to stand at a height of 2 m or more to install bearers

andjoists,acontinuousfalsedeckshouldbeprovided(seeFigure

4below).Thisisafulldeckthatisthesameareaastheoorbeing

formedbutupto2mbelowthetruedeck.Asindicatedinsection4.1

above,thedistancebetweenthefalsedeckandthetruedeckcanbe

increasedwhereaworkplatformisused.However,thefalldistance

from the work platform to the false deck must not exceed 2 m.

The false deck should be continuous both inside and between

formworkframesandtypicallyconsistsofformply,scaffoldplanksor

modularplatformsections.Aprotectedaccessopeningcanbeleftin

the deck for lifting in materials.

The use of a captive platform is preferable to lapped planks

because a captive system cannot be accidentally dislodged and its

constructionalsominimisestriphazards.Lappedplanksmayonly

be used if they are secured against uplift and slippage. The false

deckshouldbeconstructedsuchthatnogapexceeds225mmin

width and gaps only exist where a vertical member of a frame passes

through the deck.

The false deck should be designed to have adequate strength to

support:

anyonerequiredtostandonthedeck

materialsthatneedtobeonthedeck

anymaterialsorworkersthatshouldhappentofall.

The deck must be able to withstand:

apointloadof2kNdistributedoveranareaof100x100mm

(2kNisapproximatelyequivalenttoamassof200kg)

auniformlydistributedloadof2kPa,whichisequivalenttoa

mass of 200 kg per m2.

Whenconsideringthedesignofthedeckforerecting,alteringor

dismantlingformwork,theweightofthefalsedeckandanyadditional

live loads must be applied to the analysis of the formwork support

structure.

The height between the false deck and the pouring deck should allow

comfortable access for a person during stripping.

4.1.3 eti a

Anyoneinvolvedinerectingformworkframesmustbetrainedto

dothissafely.Apersonsupervisingtheerectionofformworkframe

systemsmustbeacompetentperson(asdenedinAppendix1).

TheOHSWRegulationsprovidetherequirementsfortrainingand

responsibilities of workers performing a class of high risk work.

In cases where scaffold equipment is used as a formwork support

structureanditispossibleforapersonorobjecttofall4mormore

fromthescaffold,theOHSWRegulationsrequireapersontohold:

aBasicScaffoldinglicence(SB)toerectproprietaryframes

or

anIntermediateScaffoldinglicence(SI)toerecttubeand

ttingscaffold.

Traineesarepermittedtoperformscaffoldwork,providedtheyare

under the direct supervision of a competent person who holds the

scaffolding licence necessary for the task.

Formworkframesshouldbeerectedinaprogressivemannerto

ensureboththeinstallerssafetyandthestabilityoftheoverall

structure.Bracingistobeattachedtotheframesassoonas

practicable. The risk of a fall from edges of formwork frames during

theirerectionishigh.Inthissituation,itisnecessarytoinstalledge

protection on the frames as they are erected.

Conventionalformworkframesincludediagonallyhingedbracesthat

crossinthemiddle.Whilethesebracesarenotconsideredtobe

suitableedgeprotectionforacompletedformworkdeck,basedona

riskassessment,theymayprovidereasonablefallprotectionduring

frameerection.Suchfallprotectionexistsonlywhenbracesare

installedimmediately,andinaprogressivemanner.

Figure 4 A alse deck

Gap not to exceed 225 mm


13/3712

Astheheightofformworkframesincreases,thereisagreaterneed

toprovidelateralstabilitytotheframestructure.Allframingmustbe

carried out so that it complies with on-site design documentation and

anymanufacturersrequirements.

4.1.4 Itai a

Whenpositioningbearers,installersmustbelocatednomorethan

2mfromtheoororthefallarrestingplatformlocatedimmediately

belowthem.Forexample,bearerscanbeliftedontothetopofthe

formwork frame by a person standing on a work platform erected

withintheframeandnomorethan2mfromtheoororfalsedeck

locatedimmediatelybelow(seeFigure5below).

Bearersmustbepositionedsuchthattheywillnotfallfromthe

frames. The common methods of ensuring this are to place the

bearersinU-headsontopoftheframesandalsobyensuring

cantileversareminimised.WhereonlysinglebearersareplacedintheU-head,thebearermustbeplacedandxedcentrallyinthe

U-headunlessaformworkdesignerorengineerstatesotherwise.

4.1.5 Itai it

Whereafalsedeckisprovidedat2morlessbelowformworklevel,

joists may be spread on the bearers with the worker standing on the

false deck. If the height of the formwork deck being constructed is

morethan2maboveacontinuousdeckorsurface,joistsmustbe

spreadfromaworkplatform,atleasttwoplankswide,andlocated

within 2 m of the surface underneath the deck being constructed(refertoFigure5).

Oneexampleofaworksystemthatmaybeusedtodothisis

as follows:

The joists are lited by the workers and spread on top o the

bearers into their approximate fnal positions whilst standing on a

lower work platorm. The platorm below the deck must be

positioned at a comortable height or handling joists (without

introducing manual task risks) and not greater than

2 m rom the alse deck.

4.1.6 fa ptti th w d

Continualmodicationoffallprotectionmeasuresisnecessary

during formwork construction because the structure is constantly

changing.Oneofthebiggestchallengesistoprovideadequatefall

protection on the leading edge of the formwork deck.

Wherethereisonlyoneleadingedge(i.e.theotheredgesareprovidedwithscaffoldingedgeprotection),theprovisionoffall

protectionisrelativelystraightforward.However,wherethereare

multiple leading edges and/or the deck is not at one consistent

level,theprovisionoffallprotectioncanbedifculttoimplement.

Designersofbuildingsarethereforeencouragedtodesignoorslabs

thatareoneconsistentthickness(refertosection2.1.1Buildability).

Leadingedgeandperimeterprotectionmustbeprovidedonedges

where the potential fall distance is 2 m or more and a person is not

preventedfrombeingwithin1.8moftheedge.Controlmeasuresare

requiredwhereapersoncouldfall,fromanyheight,ontoanobject

suchasframes,reinforcingsteelorarubbishskip.

Figure 5 Setting U-heads, bearers and joists

rom a two-plank platorm

2.0


14/3713

4.1.7 ed ptti th w d

4.1.7.1 fw tti z phia ai

Aphysicalbarriershouldbeprovidedandmaintainedtoseparatethe

formworkworkzonefromotherworkers.Thisbarriermustberigid,

capable of maintaining its integrity in an upright position and capable

ofsupportingsignageifrequired(seeFigures6aand6babove).

The use o ags and tape or unsupported barriers is not

acceptable.

Wherethedesignoftheformworkiscomplexandtheproleof

thedeckisconstantlychanging,constructionofleadingedge

protectionmaycreatemorehazardsthanitwouldcontrol.Insuch

cases,itmaybeimpracticaltoprovideedgeprotection,asanyone

installing the edge protection would be exposed to the risk of falls.

In some situations perimeter edge protection must be installed.

Examplesinclude:

wherethereisachangeindeckheightalongthesideofthedeck

beingconstructed,(i.e.adropdownforabeam)andnojoistsor

form ply have yet been installed at this different height

wherealeadingedgeistobeleftunattendedandaccessonto

thedeckisrequiredbyanyoneotherthanformworkers(i.e.the

formwork deck has not been barricaded off and marked with

keepoutsigns).

4.1.7.2 ed ptti ptd d

The most effective means of providing edge protection on a

completed formwork deck is to install perimeter scaffolding.

Scaffoldingiserectedpriortotheformworkand,therefore,prevents workers falling from the completed deck. The advantages

ofthissystemarethatedgeprotectionforinstallersofthenal

perimeterformplysheetsisalreadyinplace,thereisnorequirement

toinstalledgeprotectionontheperimeter,andnoexposuretoarisk

of falling.

Insomeraresituations,itmaybeimpracticaltoprovideperimeter

scaffolding.Insuchcases,edgeprotectionmustbeinstalledandthe

work system used for this installation must include a control measure

against the risk of a fall.

Theuseofharnesssystemsisdiscouraged,becauseitdoes

not provide an adequate level of protection from injury and is an

impractical control for the risk of a fall from height in formwork

erection(refertosection1.1ofthisguide).

Insomesituations,edgeprotectioncanbesubstitutedwithan

alternativemeasure,providedthismeasurepreventsapersonfalling

fromtheedge.Onealternativeistheprovisionofabarricade,1.8m

fromtheedgewithclearlyvisiblekeepoutsigns.

Furtherguidanceonstanchions,guardrails(handrails)andmid

railsforminimumstrengthandrigidityisspeciedinAS 1657 Fixed

platorms, walkways, stairways and ladders Design, construction

and installation.

Wherescaffoldingisover4minheight,onlylicensedandauthorised

scaffoldersmayerect,dismantleoralterthescaffolding.Anyscaffolding components that are temporarily removed must be

replacedattheearliestopportunity.Anygapsbetweenacompleted

oorandscaffolding,thatmayexistaftertheformworksupport

systemisremoved,mustbecoveredwherethereisariskofa

person or materials falling through.

4.1.8 lai a w d

4.1.8.1 gtti tatd a a

Afterthesupportingframes,bearersandjoistsareinposition,the

rstessentialconsiderationinlayingaformworkdeckisthatall

building work conducted at height requires some type of perimeter

protection.Thesecondessentialconsiderationisthat,forfall

prevention,workersmuststayawayfromaleadingedge.Howthese

essential elements are achieved is determined by the builder.

Figure 6a General view Figure 6b Fixing detail

Acceptable solid work zone barrier with No-Go zone below


15/3714

Therststepinlayingoutaformworkdeckistoprovidesafeaccess

andaheavydutybaytoloadandstorematerials,particularlyapack

offormply,attheformheight.Successfulsolutionswillbepartially

guidedbythesiteitself,thesizeofthejoborthecontractors

preferredsystem,andmaybeanengineeredsolution,ascaffold

solutionoraformworksupportsystemsolution.Eachhasadvantagesand disadvantages.

eid ti

Generally,engineeredsolutionsareeconomicaltoassemble,

disassemble,useandmaintain,andmaybedesignedforahigher

load-carryingcapacity(withsufcientsupportframecapacity).They

are more suitable for larger projects with more site room.

Engineereddeckunitsarepositionedandliftedbymechanical

aids,suchasmulti-purposetoolcarrier,forkliftorcrane,thus

reducing the risk of injury from manual tasks. Drop-in hand railing

systemsareeasilyinstalledatgroundlevel,reducingtheriskoffalls

during erection.

However,engineeredsolutionsgenerallyhaveahighercapitalcost

todevelop,manufactureorpurchase.Engineeredsolutionsareless

exiblebecausetheremustbeaclearaccesswayof450mm.This

limitsavailablespaceforstorageofmaterialsonthedeck(seeFigure

7below).

sad ti

Scaffoldsolutionsmaybemoreexibleintheirarrangementand

would normally require a lower initial capital investment than

engineered solutions. They are generally more suitable for smaller

jobsandrestrictedsites.Scaffoldsystemloadingbaysaremanually

erected,withtheplatformareaandhandrailsbeinginstalledat

height,increasingtheriskoffallsduringerection.

The load carrying capacity of scaffold-based systems is generally

lowerthanengineeredsolutions,beingheldwithintheallowable

limits forAS/NZS 1576.1:2010 Scaolding Part 1: General

Requirements.However,scaffoldingmaybespecicallydesigned

forhigherloads.Workplatformsdesignedforhigherloadsmust

prominentlydisplayasignindicatingtheSLL.

Scaffold-basedsystemsaregenerallymoreadaptableinallowing

forincreasedsizeofstoreditems,notnecessarilybeinglimitedtothesizerequirementsof2400x1800mmformplysheets,whilst

maintainingthenecessary600mmminimumaccesswidth.

fw ppt t ti

Packsofformplysheetsmaybeplaceddirectlyonthejoistsofa

formworksupportsystemundercertaincircumstances.Asection

of the formwork support system may be a nominated loading area

providing:

thenominatedloadingareaiscertiedbytheengineeror

formwork designer

themaximumSLLoftheareaismarkedontheformwork

drawings,togetherwithadditionalproppingrequirements

Figure 7 Engineered loading bay.

Note: Drop-in handrails in place, liting eyes, orklit slots, and built-in bearers


16/3715

anynecessaryadditionalpropsareinstalledandinspectedprior

to loading

aperimeterscaffoldisinplaceforfallprotection

theloadingareaissafelyaccessiblefromaperimeterscaffoldor

other safe access structure

alljoistsandbearersformingpartoftheloadingareaare adequatelysecuredinpositiontopreventafall,asdescribedin

section4.1.8.3ofthisguide

layingtheformplydeckproceedsasdescribedinsection

4.1.8.3ofthisguide

astartingpointforlayingthedeckisclosetotheformply

stack so as to minimise worker exposure to the risks of injury

from manually handling the form ply sheets.

4.1.8.2 Tpia w t a adi d

The following work system may be used to construct the formworkdeck for typical multi-level construction. The work system is

specicallyintendedforsituationswheretheverticaldistance

belowthedeckbeingconstructedisgreaterthan2m,butwiththe

use of false decks may be used irrespective of the distance to the

oorbelow.

1. PlacebearersontheU-headsoftheformworkframesfromthe

workingplatformprovidedimmediatelybelow.Securebearers

topreventmovement,i.e.bynailingto,orwedgingin,the

U-headsbeforejoistsareplacedontop.Noeccentric(un-

centred)loadsshouldbeappliedtotheU-headsunless

specicallyallowedbytheformworkdesigner.

2. Placejoistsonthebearersinaprogressivemannerfromthe

work platform located directly below the area to be worked

on,andspacedat450mmcentres(maximum)orsothatthegap

betweenjoistsdoesnotexceed400mm.Securethejoists

against any movement should a worker fall onto them.

3. Secureanycantileveredbearersandjoiststopreventupliftor

dislodgement prior to anyone working on them.

4. Layoutformply,orotherdeckmaterial,progressivelyas

describedinsection4.1.8.3.Whereverpossible,thedirectionof

theleadingedgeshouldbeperpendiculartothejoists,i.e.

paralleltothebearers(referFigure8).

Formplyshouldbeplacedonthejoistswiththeinstaller

located behind the sheet as it is positioned whilst standing on

the previously laid sheet or work platform provided. If this is

doneconsistently,shouldapersontriporstumbletheywould

fall onto the sheet and not from the leading edge.

Planningshouldtakeintoaccounttheoptimumpositionfor

theloadingbay,ordirectionofformplyplacementsothatlaying out of the sheets starts at the loading bay where the

formplyisinitiallystacked,reducingtheneedformanual

handling and carrying sheets.

5. Coverorprotectallpenetrationsleftbehindtheleadingedge.

Coversmustbesecurelyxedandclearlysignedtoindicatethey

areprotectingapenetration(seesection4.1.10).

6. Nailorotherwisesecureformplytothejoistsassoonas

practicable.

Iftimbershavenotbeenxed,edgeprotectioncomplying

withOHSWRegulations2010(Division13Preventionof

Falls),mustbeerectedleadingawayfromthesidesofthe

leading edge.

Onlypersonnelinvolvedintheconstructionoftheformwork

maybelocatedintheformworkconstructionzone.Anyone

not involved in this process should be excluded.

Theleadingedgemustbefreeofoil,sawdustand

obstructions to reduce the likelihood of slips and trips.

4.1.8.3 lai a p d

Aformworkdeckmustbelaidinaprogressivewaythatincludesa

method of preventing falls below the deck. This control measure is

particularly important in situations where a false deck has not been

providedwithin2mbelowthelevelofthedecktobelaid,andthe

potential fall distance is therefore greater than 2 m.

Whereafalsedeckhasnotbeenprovidedwithin2m,formplymay

only be spread on the joists where:

aminimumoffourjoistsat450mmcentres(400mmgaps,

totalling1.8m)arelocatedonbearersnexttotheperson,

andthejoistsextendforatleast1.8mallround(seeFigure8).

Therefore,intheeventofafall,thepersonwillfallontothejoists

and be prevented from falling further

layingtheformplysheetscommencesfromtheperimeter

scaffolding or other edge protection that has been provided at

theperimeteroftheformwork,e.g.attheloadingbaywheretheform ply is stacked

theformplyislaidinfrontofthebodysothatifthereisa

stumble,thefallislikelytobeontopofthesheetsbeinglaid

Figure 8 Maximum spacing o timbers around worker

where alse deck is over 2 m below

400 mm

1.8 m

1.8 m


17/3716

joistsarexedtopreventsidewaysmovement.Insome

situations,theremaybeapossibilityofapersonfallingthrough

thejoistsifthejoistsspreadasthepersonsbodymakescontact

with them during a fall. This is more likely to be a potential

hazardwhenthepersonsfallisinthesamedirectionasthe

layofthejoists.Fixingjoiststopreventsidewaysmovementwillminimise this possibility.

4.1.8.4 lai a ta d

Ametaldeckshouldbelaidinaprogressiveway.Whereafalsedeck

has not been provided within 2 m below the level of the deck to be

laid,metaldecksmayonlybelaidwheretheuseoffallprevention

systemshavebeenprovided.Worksystemsfollowingthehierarchy

ofcontrolsmustbeused.Examplesincludeelevatingworkplatforms,

scaffolding,personalfallprotectionsystemsandanti-glaremeasures

(refertoFigure9).

4.1.9 cati qit

AS/NZS 4576: 1995 Guidelines or Scaoldingrequires that

the design of cantilevered scaffolds and the adequacies of their

supportingstructuresmustbeveriedforcompliancewiththe

relevant requirements ofAS/NZS 1576.1 Scaolding Part 1: General

Requirementsbyacompetentperson,suchasanengineerwith

experience in structural design.

Cantileveredbearers,joistsandplysheetscanbehazardouswhen

left unsecured. The weight of a person standing on the cantilevermaycausetilting,resultinginthepersonormaterialfalling.

Formworksystemdesignersshouldminimisetheuseofcantilevers

wherepossible.However,insomesituationswherecantilevered

sectionsareunavoidable,theformworkdesignerorengineer

must consider the potential for people and stored materials to

causecantileverstopivot.Formworkdesignsmustindicatewhere

cantilevers are to be positively secured so that the weight of a person

or material does not cause the section to pivot.

4.1.10 Ptati

Anypenetrationwherethereisariskthatapersonoranobjectcould

fallthroughmustbecoveredorsecurelyguarded.Openpenetrations,

suchasstairwellvoidsorpenetrationstoallowforservices,create

hazardsforanyoneonaformworkdeck.Apersonmayfallthrough

largerpenetrations,sustaininjurybysteppingintoasmallerpenetration,

oranobjectmayfallthroughtheopeningontoworkersbelow.All

penetrations must include cast-in metal mesh as a backup system.

Themeshshouldhaveasmallaperture(e.g.50x50mmmeshsize

orsmaller),andbemadeofmaterialcapableofwithstandingthepotentialimposedload.Meshprovidedoverlargepenetrationsmay

requireengineeringcerticationtoensureitcanwithstandpotential

loadsincludingpeople,equipmentandmaterials.

Whereholesarecutinthemeshforservicestopassthrough,the

holeshouldbecuttotheproleoftheservicesothatmeshremains

covering the penetration.

Ungradedplywoodcoversarenotadequatebecause:

thecovermaybeindistinguishablefromotherpiecesofply

itmaybedifculttodetermineiftheplywoodisproperlysecured securedplywoodcoverscanbeunsecuredtogainaccessand

subsequently may not be re-secured.

Figure 9 Sae Work System or laying metal deck

(Note:Fallpreventionsystems)


18/3717

Plywoodcoversmustbe:

structurallygradedandsound

aminimumof17mmthick

paintedabrightcolour

non-slip

markedwiththewordsDAnger PeneTrATIon beloW.

Thecovershouldbermlysecuredtotheconcreteanddesigned

forpotentialloadsthatmaybeapplied.RefertoFigure10foran

acceptablepenetrationprotectiondesign.Beforestrippingformwork,

ensure the penetration that will be exposed is securely covered and

protected.

Penetrationsarealsohazardousbeforethedeckislaid.Joists

placed up to the edge of the penetration must be secured so that the

timbers cannot spread if a person falls on them.

4.1.11 Wi z w ad th

Theformworkconstructionzonemustbesufcientlylargetoensure

that formwork areas are clearly separated from other work areas.

Aformworkconstructiononlyzonemustbemaintainedbehind

theleadingedge.Thiszonemustbeclearlydemarcatedbysignageandameshbarrier.Figure11illustratestheotherworkzone,the

formworkzoneandthearearetainedasedgeprotection(fourjoists

spaced1800mmbeyondthelaiddeck).

Figure 10 Example o acceptable penetration protection

*Reer to 4.1.7.1 Formwork construction zone physical barriers

Figure 11 End view o deck showing working zones

100 mm

(min)

100 mm

(min)

DAngerPeneTrATIon

beloWSLL where required

Zone for

oTHer

Workers

formWork

consTrucTIon

Zone

This distance may vary

depending on work

requirements

Physicalbarrier*

Dynabolt,orsimilar

anchorage

exap i

Min17mmthick 50mmmeshcastincentrally

FloorslabFloorslab


19/3718

4.1.12 Changingoorlevels

Formworkdecksmaynotbeatacrosstheentireoor,dueto

deepbeamsordropdowns(sometimescalledcapitals)around

columns.Suchvariable,unevenoorsintroducetripandfallhazards

duringformworkerection.Itispreferablethatthesehazardsare

eliminatedatthedesignstage(seesection2.1.1Buildability).

Fallandtriphazardssuchasthesearemosteffectivelymanaged

by ensuring that lower level formwork supports and decks are

progressively constructed before work commences on the higher-

level areas of the deck.

4.2 formWork erecTIon moDulAr

formWork sysTems

4.2.1 bai da t

Thebasicprinciplesdiscussedinsection4.1ofthisguideontraditional systems apply to the erection of modular formwork

systems.Althoughtheerectiontechniqueandmemberdimensions

mayvarygreatlybetweentraditionalsystemsandmodularsystems,

the principles of maximum potential fall distance and gap width at

the working level are applicable:

thewidthofanygaponaworkinglevelisnottoexceed

400mmunlessafalsedeckhasbeenprovidedwithin2m

of the working level

workingplatformsusedformodularsystemsmustalsohave

aminimumwidthof450mm.Bothmodularandtraditionalformworksystemsmustbedesigned

to comply with the loadings and general principles ofAS 3610:

Formwork or Concrete.

Traditional formwork systems are sometimes used adjacent and

connectedtomodularsystems,particularlyforunusuallyshaped

areas.Wherethisisthecase,theformworkdrawingsshouldshow

anyessentialconnectionordesigndetailsandbecertiedbyan

engineerorformworkdesigner.However,componentsfromone

proprietary type of formwork system should not be used as integral

parts of other modular formwork systems unless the designer of themodular system states in writing that this is permitted.

Modularformworksystemsareoftenmanufacturedfromaluminium

insteadofsteelandarethereforelighterinweight.Beinglightweight,

theyrequirelessphysicalefforttoerectthantraditionalsystems,and

alsotheneedforrepetitivehammeringmaybeeliminated,reducing

workersexposuretotheriskofinjuryfrommanualtasks.

Becausemodularsystemsarelighterinweighttheymaybemore

susceptible to overturning during erection when exposed to eccentric

loading factors such as wind loading etc. This is generally an issue

only prior to placement of the decking on the modular support

system.Toeffectivelycontrolanyinstability,modularformwork

systems must be progressively braced during erection in accordance

withthemanufacturersinstructions.

4.2.2 Taii

Workersinvolvedintheerectionofmodularformworksystemsmust

be trained in the safe erection and dismantling of the system and the

inspectioncriteriaforcomponents,particularlyfordefectsthatwould

preclude their use.

The modular system supplier or designer should provide written

instructions for the erection and dismantling of the system.

Instructions should include safety instructions equivalent to those

detailed in this guide.

Trainingbythemodularformworksystemsupplierisencouraged.For

trainingrequirementsrefertoAppendix2.

4.3 sTrIPPIng formWork

Strippingformworkcanbeoneofthemosthazardousphasesof

concrete construction.

Whilefallingobjectsaretheprimaryhazard,theremayalsobefall

hazardsasaresultofoor,scaffoldorformworkcollapse,aswellas

manualtaskhazardsfromapersonworkinginawkwardpostures,

repetitivehandlingofmaterials,orlimitedtaskvariety.

Workersmustbeinformedoftherisksandbeadequatelytrained,

sothatstrippingoperationsarecarriedoutinanorderly,progressive

manner,asoccurswithformworkerection.

4.3.1 ga w tippi

To reduce the risk of injury when stripping formwork/false work:

installfully-deckedworkplatformsataheightnogreater

than 2 m from ground level or the catch deck

erectacatchdecknomorethan2mbelowtheworkarea

suitablybarricadeandsignpostthestrippingarea

(withbarriermeshasaminimum).

4.3.2 sa w thd tatt

Onlyanexperiencedandcompetentpersonshouldpreparesafe

workmethodstatementsforthestrippingoperation.Properly

prepared statements are very useful as a training tool for those

who will be involved in this high risk activity. The safe work method

statement should detail factors such as:

thehazardsrelatedtothestrippingprocessandanyequipment

and strategies to eliminate or minimise the risks

thenumberofpeopleinthestrippingcrew

thesequenceofstrippingactivitiese.g.detailinghowtheframes

and/orothersupportsaretoberemovedandhowfarU-heads

may be lowered

whetherthesupportsystemmaybecompletelyremovedina

zonepriortoremovaloftheformworkdeck,orwhetherthe

supports are to be lowered slightly but still remain under the form

ply while it is being removed


20/3719

whenback-proppingisrequiredoronlypartofthesupport

systemistoberemoved,howthestructuralmembersareto

remain in place and/or the type and layout of members that will

replace the formwork system

anyotherspecialrequirementsinvolvedinthestrippingand

or building processes e.g. checking of back-propping afterpost-tensioning.

4.3.3 Certicationpriortostripping

Priortocommencementofthestrippingoperation,anengineermust

providewrittencerticationthatformworkcanberemoved.This

certicationshouldbebasedonanengineersspecicationsforthe

building,thestrengthoftheconcretemixandthetimeperiodthat

has elapsed since the pour.

Anengineermayalsoberequiredtohaveinputintothestripping

safe work method statement to ensure the concrete element

doesnotfail,andmustprovidesufcientdetailonthestructural

engineeringdrawingsasrequiredbysection17Formworkof

AS 3600 Concrete Structures.

Documentation from the concrete supplier verifying the concrete

specicationshouldbeavailableonrequest.Aconcretesampling

and testing procedure should be in place to verify that concrete

meetsitsdesignspecicationforstrippingpurposes.Guidance

on sampling and testing systems for concrete is provided in

AS 1379:2007 Specifcation and Supply o Concrete.

4.3.4 exi z

Onlythoseinvolvedinthestrippingoperationarepermittedinan

areatobestripped.Strippingareasmustbecordonedoffand

signs displayed to keep non-essential personnel out of the area

e.g. DAnger formWork sTrIPPIng In Progress

AuTHorIseD Persons only.

Itispreferabletorestrictaccesstothewholeoorwheresoft

strippingistakingplace.Thiswouldnotonlybesafer,butalso

reduces the quantity of signage and barricades required.

Whereothertradesorsub-contractorsarerequiredtoworkonthe

sameoorduringthestrippingofwalls,columnsorsmallsectionsof

soft,theprincipalcontractororemployermustensurethatcontrols

are applied to prevent non-essential personnel from entering the

stripping area.

4.3.5 Dp tippi

Drop stripping is an unsafe method of work and cannot be supported

by this guidance document. In cases where drop stripping is being

considered,theformworkandsupportdesign,andtheconcreteelementdesign,shouldbereviewedbythedesignerandmodiedto

eliminate drop stripping.

4.3.6 bd dti

Strippingofformworkmaybeaidedbyreducingthebondbetween

theformmaterialandtheconcrete.Bondstrengthisdependenton

thematerialcharacteristics,thesmoothnessoftheformmaterial

and age of the concrete. The use of a liquid bond breaker on wall

and column forms is one way of reducing the strength of the bond.

However,theuseofbondbreakeronoorformsisnotencouraged

becauseofthesliphazardthatmayresult.

4.4 crAne AnD oTHer loAD HAnDlIng sysTems

4.4.1 ladi atia di w tti

Formworkstructuresarenotnecessarilysafetoacceptanyexcess

loadinguntiltheyarefully-secured.Thatis,untilafterthedeckisin

placewithtie-insandproppingcomplete,andanyproposedloading

areacertied.

Inpractice,someloadingoccursbeforeadeckiscompleted

e.g. unloading pallets of ply and joists on a partially constructed

formworkstructure,tocontinuethedeck.Thisisanunacceptable

and dangerous practice which could lead to a full structural collapse

ofthedeck,possiblyresultinginseriousorfatalinjury.Toensurethe

integralsafetyofthedeck,materialsmayonlybestoredwhereand

whenthedeckiscertiedasabletobeartheload.

Formworkersandcranecrewsmustbemadeawareofthespecic

locationsandloadsforcertiedloadingareas,andthatstacked

materialsmaycreatepointloadings,whichaformworkstructuremaynot be designed to bear at that point.

Tominimisetheriskofcollapseandotherhazards:

loadsmustnotbeplacedontheformworkdeckifthe

formwork documentation prohibits loading

formworkdrawingsmustclearlyidentifythelocationsand

SLLformaximum(pre-pour)pointloadingsforthedeck.These

locationsmustbespeciedbyaformworkdesignerorengineer

cranecrewsmaynotliftmaterialsontothedeckuntilthereisa

designatedliftingzone

cranecrewsmustbenotiedwhenanareaofdeckisreadyto

takeaload,andspeciedloadsmayonlybeplacedinthearea/s

designated and placed so that they cannot fall

deliveryofmaterialstothesiteshouldbeplannedsothatloads

are not lifted onto unsecured decks

priortoworkersleavingthesite,materialsandequipmentshould

be secured to prevent them being moved by wind.

4.4.2 sii ad

Slingingandun-slingingloadsatheightisalwaysahighriskactivity.

Safeworkmethodsandfallpreventionsystemsareessentialforthis

activity(refertosection4.1.8.1)

Adogman,orotherpersonengagedinslingingloads,mustbe

provided with adequate fall protection and a safe means of access


21/3720

when working at 2 m or more above the deck.

The use of fall arrest systems for workers slinging formwork

loadsisusuallyimpracticalandisnotrecommended.However,it

maybereasonablypracticabletotplatformsandedgeprotection

as fall protection.

4.4.3 liti a

Guidanceontheuseandinspectionofchains,wireropesand

synthetic slings is provided in the following publications:

AS 2759: 2004 Steel wire rope Use, operation and

maintenance

AS 3775.2: 2004 Chain slings Grade T Part 2: Care and use

AS 1353.2: 1997 Flat synthetic webbing slings Part 2: Care

and use.

Basicitemsthatneedtobecheckedinclude:

liftinggearistaggedandallrelevantinformationlisted

(e.g.relevantinformationforachainslingisgradeofchain,

safeworkingload,manufacturer,chainsizeandAustralian

Standardmarking)

liftinghookshaveoperablesafetylatches

liftingeyesandinsertsarecompatible

liftingslingsareserviceableandnotdamaged(i.e.haveno

excessivewear,damagedstrands,cracks,deformationand/or

severecorrosion)

syntheticbreslingsaremaintainedingoodcondition,arerated fortheloadbeinglifted,haveasuitableslingingconguration

and are protected from sharp edges.

Itismostimportantthatallliftinggearincludingslings,hooks,wire

ropes,pendantsandmaterialboxesareperiodicallyinspectedfor

damage and wear. The period between inspections may depend on

the severity of use with the exception of:

chainslings,whereinspectionsmustnotexceed12months

syntheticbreslings,whereinspectionfordamagemustbe

undertaken before each use and full inspection at least every

threemonths.Refertosection9ofAS 1353 .2: 1997 Flat

synthetic webbing slings, part2:Careanduseforinspection

itemsandsection11forDiscardCriteria.

Documented maintenance records for the lifting gear should be

available for inspection on-site.

4.4.4 liti w atia

Crane-liftedloadsmustbeslungandsecuredsothattheload

(oranypartofit)cannotfall.

Weightsofwall,liftorcolumnformsshouldbeprovidedon-sitewith formwork documentation and made available for inspection

by all interested parties.

SLLsmustbeclearlymarkedonbins.

Liftingboxesintendedforliftingpeoplemustbedesign

registeredwithSafeWorkSAandsuitablyconstructedforother

material being lifted.

Fourchains(oneineachcorner)mustbettedtoliftboxesto

maintain stability.

Liftingboxesmustbeinspected,maintained,andinspectionrecords kept.

Specically-designedliftingboxesshouldbeusedtoliftsmaller

components(e.g.spigots,U-heads,baseplatesandcouplers).

Boxesmusthaveenclosedsidesorrobustmesh(withopenings

lessthantheminimumsizeofmaterialsbeinglifted).

Loadscontainedwithinliftingboxesshouldbesecured

against movement.

Materialsmustnotbestackedhigherthanthesideofthebox

unless they are adequately secured.

Formworksupportframesmusteitherbetiedtogetheror

secured with lifting slings wrapped around the load.

Loadsofjoistsorbearersshouldbestrappedtogether

before lifting.

Taglinesmustbeusedtocontrolloadsandforms,andmust

bexedtotheload,nottheliftinggear.

Formplyloadsshouldbestrappedtogetherandliftedina

atposition.

Ensure,wherepossible,thatallloadsaresupportedondunnage

and the load is uniformly distributed over the supporting surface.

Priortoliftinganyitems:

removeanywasteconcreteetc.fromformsoranyother

materials or equipment to be lifted to ensure the waste does not

fall onto people below

inspectallloadscloselytoensureallloosematerialsandtools

have been removed.

4.4.5 liti

Chainslingsattachedtolugsorholescutintopartofaloadareoften

usedtoliftbins,wall,liftwellorcolumnforms(insteadofwrapping

theliftingslingsaroundtheload).Informationverifyingthestructural

adequacy of the lifting points must be available.

Anengineermustverify:

thestructuraladequacyoftheliftinglug

themeansofattachmenttotheload(usuallyweldedorbolted).

4.5 use of lADDers

Laddersmustbesecuredatthetoporbase,orwhenthisis

impractical,heldrmlyatthebasebyanotherperson.

Wherepracticable,alternativestoladderssuchasworkplatformsor

stairaccesssystemsmustbeused.Fixedorpermanentladdersmustcomply withAS 1657 Fixed platorms, walkways, stairways and

ladders Design, construction and installation.


22/3721

Whereladdersareprovidedasaccesstoalivedeck:

theymustextendatleastonemetreabovetheaccessed

surface,besecuredagainstmovementandbesetuponarm,

level surface

theymustbeofindustrialstandardwithaloadratingofat

least 120 kg

singleandextensionladdersmustbeplacedatanangleof

between70degreesand80degreestothehorizontal

(4up,1outrule),exceptinsomeraresituationswherethis

is impractical

singleladdersmustnotexceed6.1minlengthandextension

laddersmustnotexceed7.5m.

Otherissuesregardingthesafeuseofladdersinclude:

metalormetalreinforcedladdersmustnotbeusedinthevicinity

ofliveelectricalequipment.TheOfceoftheTechnicalRegulator (OTR)providesinformationoncompliancewithsafeworking

distances in the vicinity of live electrical wires

nevertouchaladderthatisincontactwithelectricalpowerlines

apersonsfeetmustalwaysbemorethan1mfromthetopof

the ladder

laddersarenottobeusedonscaffoldingorelevatedwork

platforms to gain extra height

laddersmustnotbepositionedaboveoradjacenttoopeningsor

edgeswhereapotentialfallcouldoccur.Aworkplatformwith

edge protection should be used instead

laddersshouldnotbeusedinaccesswaysorwherethereis pedestrian,vehicularormobileplanttrafcunlessarisk

assessment has been undertaken and other precautions have

been considered

alwaysmaintainthreepointsofcontactwhenusingladders.

5. spia qit wa ad

5.1 brAcIng for WInD loADIng

Wallandcolumnformsmustbedesignedtowithstandalllive

anddeadloads,includingwindloadpriorto,during,andafterthe

concrete pour. The bracing and forms must not be removed from

thecastelementuntilitissufcientlymaturetosafelywithstand

potential impact loads and wind loads.

Priortostripping,anengineerorothercompetentpersonmust

providewrittencerticationthattheformworkcanberemoved.

Bracingmustbedesignedtosuititsapplicationandveriedbythe

designer(refertosection2.2.1).Bracingelementsmustbedesigned

and installed to resist both positive and negative wind generatedloads.Bracinganchorsshouldpreferablybecast-intypeorthrough-

boltsthatextendthroughbothsidesoftheanchoringmedium.

Drill-inanchorsofthefollowingtypemaybeused,providedtheyare

installedinaccordancewiththemanufacturersinstructions:

undercuttypeanchorthatdoesnotrelyonfrictiontofunction

expansionanchorsofthehigh-loadslip,torquecontrolledtype

coilbolts.Thecorrectoperationofcoilboltsisgreatlydependent

on whether they are installed in accordance with a

manufacturersspecications(e.g.drillingthecorrectsizedhole

andapplyingthecorrecttorqueinconcreteofadequatestrength).

Drill-intypeanchorsmayhaveaspecicinstallationtorqueset

requirement to function correctly. Torque measurements should be

madeusinganaccuratelyadjustabletorquewrench.Analternative

method that may be used to verify the torque could be a calibrated

rattlegun.Recordsverifyingthesettingtorqueforalldrill-intype

anchorsshouldbeavailableon-site.Manufacturersnormallyspecify

the minimum distance from a concrete edge that an expansion

anchor may be installed.

5.2 Access PlATforms

Mobilescaffolding,purposebuiltworkplatformsorelevatingwork

platforms may be suitable in providing the essential safe access to

elevatedworkareasfordogmen,steelxersandconcreters.Edge

protection must be provided on any access platform.

Platformsmustbedesignedtoprovidesufcientaccessandworking

spaceforthenumberofpersonnelrequiredforspecictasks,and

must be positioned at a height and distance from the form so as to

minimisereachingandstretchingmovementsandlimitapersons

necessary exertion.

Concretepouringsystemsmustprovideadequatesafeworking

space,withedgeprotectionprovided,forallworkers.

Castorsonmobileworkplatformsmustbelockedatalltimesexcept

when they are being moved.

Allplatformsmustbedesignedforstabilityandresistancetoany

sideloadingthatmaybeappliedduringaconcretepour.Lightweight

aluminium scaffolding may not have adequate stability when

subjected to side loading and may require additional bracing.

5.3 lIfTIng meTHoDs

Wallandcolumnformsmayonlybeliftedwithapositivelifting

system,suchasliftinglugsorbywrappingliftingslingsaround

theformsuchthattheformcannotslipoutoftheslings.Purpose

designedliftinglugsmustbeusedwhereverpracticable(referto

section4.4.5).

Anengineermustprovidedocumenteddesignsforwallandcolumn

formliftingpoints,andthedesigndocumentationshouldbeavailable

on-site.Whereliftinglugsareattachedtotheform,anengineermust

specifythexingorwelddesign,andthemanufacturermustensure

and certify that the attachment or weld complies with the design

requirements.


23/3722

Formingliftingpointsbycuttingholeswithoxy-acetylenetorchesis

unacceptable and must not be used as:

theloadcarryingcapacitycannotbeguaranteed

itmaydifculttoattachliftinggear

positioningoftheholemaybeinaccurate

theformmaybedamaged.

6. spia qit ip ad p

Thissectionappliestoslipforms,jumpformsandcrane-liftedforms

that incorporate working platforms and enclosed cells in which

people are required to work.

Slipformsandjumpformsaretermsgiventoself-climbingformwork

systemsspecicallyintendedtoconstructconcreteservicecores,walls and columns in high rise buildings and other concrete

structuressuchassilosandchimneys.Inslipforms,theclimbing

is usually carried out continuously during the concrete pour which

maybecompletedtofullheightinonepouringoperation.Withjump

forms,theclimbingisdoneinsteps,liftingthecompleteformunitto

thenextlevelfollowingeachconcretepour.Thetermclimbingform

isalsousedtodescribeeitheraslipformorjumpform.Climbing

operations are usually powered by hydraulic rams or electric motors

connected to climbing feet or screw shafts.

Slipformsandjumpformsusuallyconsistofanumberofdecksand

mayalsobettedwithtrailingscreensthataresuspendedfromthe

form.Aswithperimeterscreens,trailingscreensmay:

provideedgeprotection

preventmaterialsfromfalling

providesupportforworkplatforms,oracombinationof

these uses.

Notwoslipformsorjumpformswillnecessarilybeidentical,astheir

designwillbebasedonthesizeandcongurationofthestructureor

building under construction.

The work systems and layout of some crane-lifted forms may also

be similar to those associated with slip forms and jump forms. This

may be the case for crane-lifted forms provided for the inside of lift

shafts.Whilemostoftheinformationinthissectionappliestoslip

formsandjumpforms,someoftheprinciplesmayalsoapplyto

crane-lifted forms.

Whendesigningandoperatingthesetypesofformsystems,the

following issues must be addressed:

providesafeaccesstoallareasandworkplatforms

controlrisksassociatedwithworkingatheight developsafeworkmethodstatementsandusingthemtotrain

workers in the safe operation of slip and climb form systems

providesufcientworkingspaceandheadroom

specifyandprovidesafeworkmethodstatementsformanual

handlingofshuttersandothercomponents,e.g.theuseof

cranes to lift shutters and provision of safe access for workers

attaching slings to shutters

ensureadequateventilationandlightinginallworkareas

provideadequateamenitiesforworkersgiventhatslipformoperations often continue for extended shifts

alwaysuseHotWorkPermitsforslipformandjumpformsystems

ensuresufcientreextinguishersareprovided

ensureemergencyprocedures,includingfortheretrievalofan

injured or incapacitated person from any work area located

withinthestructurearedeveloped,implementedandtrialled.

It is acknowledged that it may not be practicable to provide an

access system and working environment on a jump form or slip

formthatisofthesamestandardaselsewhere.However,anyone

incontrolofaproject,taskorworkersmustcomplywiththeirobligationsundertheOHSWAct.

6.1 Access AnD egress

Accesstoslipformandjumpformsystemsmaybeprovidedina

variety of ways including one or more of the following:

personnelandmaterialhoistsonthebuilding

permanentstairsystemsinthebuilding

atrailingstairsystemsuspendedfromtheslipformorjumpform

atrailingladdersystem.

Atrailingstairsystemispreferabletoaladdersystemasitiseasier

toascendanddescend,andemergencyevacuationisgenerallysafer

and easier on a stair system. The access area between the trailing

accesssystemandthebuildingmustbeclearoftriphazardsand

thereshouldbenogapsexceeding50mmwidebetweenplatforms.

The formwork designer must ensure that a trailing access system is

designed for additional loads that could be applied in an emergency

evacuation situation. The design must ensure that not only the

strengthoftheformsystemitselfisadequate,butalsotheformwork

structure safely supports any applied loads from the access system.

Atrailingstairaccesssystemshouldbedesignedforaloadof

atleast2.5kPaunlessthedesignerspeciesotherwise.Where

thedesignerspeciesalesserliveloadthan2.5kPa,thefollowing

applies:

asignstatingthemaximumloadlimitmustbexedtothe

stairs in a visible position

writtenproceduresmustbeimplementedtoensurethetotalload

limit is not exceeded.

Laddersmustbesecuredinplaceandbeplacedatanangle

between70and80degreestothehorizontal,wherethisispractical.

Accessopeningsforladdersonworkingdecksshouldbeprovided

withtrapdoorsthatareclosedwhennotinuse,easilyopenedfrom

above,anddonotcreateatriphazardonthedeck.


24/3723

Accesswaysshouldbekeptfreeofmaterialsandrubbishtoprevent

objects falling to the level/s below.

6.2 Work PlATforms

Division13PreventionoffallsoftheOHSWRegulationsspecies

requirements for work platforms. These requirements also apply to

slipformsandjumpforms.However,thefollowingpointshighlight

specicissuesthatmayapply:

Whenplacingsteelorpouringconcreteintoaform,controls

must be implemented that prevent a person falling into or from

the form. The risk of this is higher when the form is greater

than225mmwidepriortoplacementofreinforcingsteel.

Workersmustalsobeprotectedfromtheriskofbeingimpaled

onprojectingreinforcingbarsorotherobjects.Suitablecontrols

may include edge protection on the internal side of the working

platform,orreinforcementmeshtemporarilyplacedontopof theform,enablingthesteeltobefedthroughthemesh(see

Figure12).

Thedesignandconstructionofplatformsmustincludepositive

xedsecuritysothatjammingormovementcannotoccurunder

eccentric loads e.g. where work platforms have a trailing screen ononesideandaresupportedbyabuildingparapetontheother,

uplift may occur from wind loading or where a platform is not

levelandisunsecured.Ifthisoccurs,theplatformmayjamor

otherwisemoveundertheunbalancedload,causingaperson

to fall.

Whereindividualcellsofaformareclimbedatdifferenttimes,

edge protection must be provided separately on each cell.

Safeworkmethodstatements,developedforallhigherrisk

aspectsofslipformorjumpformsystemsandaccesssystems,

will assist in ensuring safe systems are implemented and provide

a sound training aid for workers engaged in this activity.

6.3 TrAIlIng screens AnD PlATforms

Trailing screens can provide edge protection and a means of

preventing falling objects. They can also be designed to support

lower,suspendedworkingplatformsforrepairingorpatching

concrete,andtoprovideaccessforanyoneclimbingtheform.The

formworkdesignerwillneedtospecicallyaddressanddocumentall

issues for which the trailing screen system is designed. The design

must address the following:

Theremustbeasuitabledesignloadingforanyplatformson

thetrailingsystem.Asaguide,platformsmustbedesignedto

supportaminimumloadof2.5kPa.Adesignermayreduce

this if the number of people is strictly limited and controls are

implementedon-sitetoensurethespeciedloadisnot

exceeded.Ifthedesignloadislessthan2.5kPa,thismustbe

statedindocumentationkepton-siteandsignsmustbexedto

the platforms stating the maximum load permitted in kilograms.

Sitepersonnelmustbemadeawareofandcomplywiththe

maximum loading that applies to the trailing platform.

Strategiesmustbeimplementedtoadequatelycontrolthe

riskfromfallingmaterials(seesection5forfurtherguidance).

Allplatformsmustbesecuredtopreventupliftoranyother

unplanned movement.

Ariskassessmentofaformsystemmustincludetheneedfor,

anduseof,laddersandedgeprotection.Thesystemmustmeet

therequirementsoftheOHSWRegulations.

Apersonmustnotrideontrailingplatformswhiletheplatformsare being crane-lifted. If access or work is required whilst a

cranesupportsthetrailingplatform,anotherworksystemmust

be devised. This could involve another crane with a registered

workbox,oraseparateaccessscaffoldsystem.

AnyworksystemchosenmustcomplywiththeOHSW

Regulationsandincludesafeworkmethodstatementsbasedon

riskassessment,withriskcontrolstrategiesbasedonapplication

of the hierarchy of control.

6.4 clImbIng THe form

Climbingisusuallycarriedoutusingaseriesofclimbingdevices

set up to lift at the same time and at the same rate. If the lifting

system is not properly synchronised the form may become wedged

onthestructure,orstructuralmembersmaybeoverloadedand

become unstable.

There should be a systematic approach to ensure that the form

remains within level tolerances during the climbing process. The

system may be automated or may rely on operators stopping each

individualdevicecontrollingtheclimbingprocess.Whicheverprocess

isused,thefollowingmustbeobserved:

Asafeworkmethodstatementmustbedevelopedtotrain

personnel and manage the climbing process.

Figure 12 Mesh used as all protection

on wall pour


25/3724

Onlythoseworkersdirectlyinvolvedwiththeclimbingprocess

may be on the form during the climb.

Anypotentialniporshearpointswhereapersoncouldbeinjured

duringtheclimbmustbeidentiedandcontrolled.

Allobstructionsandlooseitemsontheformaretoberemoved

priortoclimbing.Aninspectionchecklistandsign-offprocedurefor this should be implemented. Items typically left on forms

includeZ-bars,ferrulebolts,insertanchors,coversand

hand tools.

Itisimportanttoensurethedifferentpartsoftheformremain

level during the climbing process.

Electricalcables,waterandotherpiped

formwork guide

Documents