Method Statement : Installing Formwork

Explanation

The installation of formwork for slabs, walls, and beams involves the assembly of proprietary shuttering panels or pans, supplemented by timber formwork components, to create a mould into which concrete is poured. This process is fundamental in providing the necessary shape and support for concrete structures during the curing phase. The primary aim of this task is to ensure that the formwork is constructed accurately and securely, maintaining structural integrity and alignment, while adhering to design specifications. Proper installation is crucial to prevent structural failures and ensure the safety of all personnel involved in the construction process.

Responsibilities

• Site Manager: Ensure all safety protocols and procedures are in place and adhered to during the installation of formwork.
• Supervisor: Oversee the installation process, ensuring that all workers are following the safe operating procedures and using the correct equipment.
• Formwork Installer: Assemble and install formwork according to the design specifications, ensuring stability and safety at all times.
• Health and Safety Officer: Conduct regular inspections to ensure compliance with health and safety regulations and address any hazards promptly.
• Engineer: Provide technical guidance on the structural integrity of the formwork and ensure it meets design requirements.
• Labourer: Assist in the manual handling and positioning of formwork components, following safe lifting techniques.
• Training Coordinator: Ensure all personnel involved in the installation are adequately trained in safe work practises and the use of equipment.

Equipment

• Hammer
• Spirit level
• Tape measure
• Power drill
• Circular saw
• Wrench
• Clamps
• Crowbar
• Shovel
• Ladder or scaffolding
• Hard hat
• Safety goggles
• High-visibility vest
• Steel-toe boots
• Gloves
• Hearing protection

Operation

• Conduct a risk assessment to identify potential hazards and implement control measures.
• Ensure all personnel involved are adequately trained and competent in formwork installation.
• Verify that all necessary personal protective equipment (PPE) is available and in good condition.
• Inspect the work area for any hazards, such as uneven surfaces or overhead obstructions.
• Confirm that all tools and equipment are in safe working order and suitable for the task.
• Review the formwork design and ensure it complies with relevant standards and specifications.
• Establish a clear communication plan among the team members.
• Ensure that appropriate lifting equipment is available for handling heavy components.
• Check weather conditions and plan accordingly to mitigate any adverse effects.
• Set up barriers and signage to restrict unauthorised access to the work area.
• Ensure that emergency procedures are in place and understood by all personnel.
• Verify that all materials required for the installation are on site and in good condition.
• Position the shuttering panels or pans according to the design specifications for slabs, walls, or beams.
• Securely fix the panels in place using appropriate fasteners, ensuring they are level and aligned.
• Assemble wall formwork by positioning panels vertically, ensuring they are plumb and aligned.
• Use timber components to fill any gaps or make adjustments as required.
• Install tie rods and braces to prevent movement during concrete placement.
• Position beam formwork components according to the design layout, ensuring supports are adequately spaced.
• Use timber components to reinforce corners and joints as necessary.
• Double-check all connections, fasteners, and braces to ensure they are secure.
• Install additional bracing if required to enhance stability, particularly in areas subject to high loads.
• Conduct a thorough inspection of the entire formwork structure to ensure compliance with design specifications and safety standards.
• Address any identified issues before proceeding with concrete pouring.
• Communicate with all team members regarding the completion of formwork installation.
• Ensure that all personnel are aware of the next steps in the construction process and any associated safety precautions.

Risk Assessment : Installing Formwork

Who might be harmed: Construction workers | Site supervisors | Subcontractors

Type of harm: Broken Bones | Death | Head Injury | Multiple / Various Injury

Initial Risk: Catastrophic (5) x Frequent (5) = High (25) Controls

• Ensure all personnel are equipped with and use appropriate fall protection equipment, such as harnesses and lanyards, when working at height.
• Install guardrails or edge protection around the perimeter of elevated work areas to prevent falls.
• Utilise scaffolding or mobile elevated work platforms (MEWPs) to provide stable access to high work areas.
• Conduct a risk assessment prior to commencing work to identify potential fall hazards and implement necessary controls.
• Ensure all workers are trained in safe working at height practises and the correct use of fall protection equipment.
• Regularly inspect all fall protection equipment and access platforms for defects or damage before use.
• Establish a clear communication system among workers to coordinate movements and ensure safety when working at height.
• Limit the number of personnel working at height simultaneously to reduce congestion and potential for accidents.

Residual Risk: Minor (1) x Improbable (1) = Low (1)

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Manual Handling Injuries : Low (1)

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Who might be harmed: Construction workers | Labourers | Formwork installers | Apprentices

Type of harm: Back / Spinal Injury | Broken Bones | Muscular Injury

Initial Risk: Severe (4) x Occasional (3) = Medium (12) Controls

• Ensure all workers are trained in proper lifting techniques specific to handling formwork components.
• Utilise mechanical aids, such as hoists or cranes, to lift and position heavy formwork panels.
• Plan the layout of the work area to minimise the distance materials need to be manually transported.
• Encourage team lifting for heavy or awkwardly shaped formwork elements to distribute the load.
• Conduct a risk assessment to identify and mitigate potential manual handling hazards before commencing work.
• Rotate tasks among workers to prevent fatigue and reduce the risk of repetitive strain injuries.
• Provide appropriate personal protective equipment, such as gloves, to improve grip and reduce strain.

Residual Risk: Minor (1) x Improbable (1) = Low (1)

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Struck by Falling Objects : Low (1)

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Who might be harmed: Construction workers | Site supervisors | Subcontractors

Type of harm: Amputation | Back / Spinal Injury | Broken Bones | Crush / Entrapment | Cuts and Abrasions | Death | Eye Damage | Head Injury | Multiple / Various Injury

Initial Risk: Severe (4) x Probable (4) = Medium (16) Controls

• Ensure all tools and materials are securely fastened or stored when working at height to prevent them from falling.
• Erect barriers or exclusion zones beneath areas where formwork is being installed to keep unauthorised personnel clear.
• Use tool lanyards to secure hand tools when working at height to prevent them from dropping.
• Conduct regular inspections of formwork and scaffolding to ensure stability and prevent accidental dislodgement of materials.
• Provide workers with appropriate personal protective equipment, such as hard hats, to protect against falling objects.
• Implement a clear communication system among workers to alert others when materials are being moved overhead.

Residual Risk: Minor (1) x Improbable (1) = Low (1)

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Exposure to Hazardous Substances : Low (1)

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Who might be harmed: Construction workers | Site supervisors | Subcontractors

Type of harm: Asbestosis / Lung Cancer / Mesothelioma | Burns | Dermatitis | Respiratory damage / Asthma / COPD

Initial Risk: Catastrophic (5) x Probable (4) = High (20) Controls

• Ensure all workers are provided with and wear appropriate personal protective equipment, such as gloves and goggles, when handling form release agents.
• Use form release agents that are less hazardous or have reduced volatile organic compounds to minimise exposure risks.
• Implement proper ventilation in enclosed areas where form release agents are applied to disperse fumes effectively.
• Provide training for workers on the safe handling and application of form release agents, including understanding safety data sheets.
• Establish designated areas for the storage and mixing of hazardous substances, away from general work areas, to prevent accidental exposure.

Residual Risk: Minor (1) x Improbable (1) = Low (1)

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Electrical Hazards : Low (1)

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Who might be harmed: Construction workers | Electricians | Site supervisors | Equipment operators | Subcontractors

Type of harm: Burns | Death | Electrocution

Initial Risk: Major (3) x Occasional (3) = Medium (9) Controls

• Ensure all power tools and electrical equipment are regularly inspected and maintained to prevent faults.
• Use only battery-operated or low-voltage tools when working near formwork to minimise electrical risks.
• Implement a lockout/tagout system to ensure that electrical circuits are de-energised before work begins.
• Provide appropriate personal protective equipment, such as insulated gloves and footwear, to workers handling electrical tools.
• Ensure that all workers are trained in recognising and avoiding electrical hazards specific to formwork installation.
• Maintain a safe distance from overhead power lines and ensure that formwork does not come into contact with them.
• Use ground-fault circuit interrupters (GFCIs) on all temporary electrical circuits to prevent electric shock.

Residual Risk: Minor (1) x Improbable (1) = Low (1)

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Trips and Slips : Low (1)

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Who might be harmed: Construction workers | Site supervisors | Subcontractors

Type of harm: Back / Spinal Injury | Broken Bones | Cuts and Abrasions | Death | Head Injury | Muscular Injury

Initial Risk: Severe (4) x Probable (4) = Medium (16) Controls

• Ensure all work areas are kept tidy and free from debris to prevent tripping hazards.
• Use non-slip footwear to provide better grip on potentially slippery surfaces.
• Install temporary lighting in poorly lit areas to improve visibility and reduce the risk of trips.
• Clearly mark and secure any uneven surfaces or changes in level to alert workers.
• Regularly inspect walkways and access routes for hazards and address them promptly.
• Ensure that all formwork components are stored safely and do not obstruct pathways.

Residual Risk: Minor (1) x Improbable (1) = Low (1)

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Collapsing Formwork : Low (1)

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Who might be harmed: Construction workers | Site supervisors | Engineers | Visitors to the site

Type of harm: Crush / Entrapment | Broken Bones | Death | Head Injury | Multiple / Various Injury

Initial Risk: Major (3) x Probable (4) = Medium (12) Controls

• Ensure all formwork components are inspected for damage or defects prior to installation.
• Use only formwork systems that are designed and rated for the specific load requirements of the project.
• Follow manufacturer’s instructions and guidelines for the assembly and installation of formwork systems.
• Implement a system of regular inspections by a competent person to verify the stability and integrity of the formwork.
• Ensure proper bracing and support are in place according to engineering specifications before pouring concrete.
• Train all personnel involved in formwork installation on correct assembly techniques and safety procedures.
• Limit access to the area beneath and around the formwork during installation and concrete pouring.
• Monitor weather conditions and postpone work if adverse conditions could compromise formwork stability.

Residual Risk: Minor (1) x Improbable (1) = Low (1)

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Inadequate Bracing : Low (1)

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Who might be harmed: Construction workers | Site supervisors | Subcontractors

Type of harm: Crush / Entrapment | Broken Bones | Death | Head Injury | Multiple / Various Injury

Initial Risk: Catastrophic (5) x Probable (4) = High (20) Controls

• Ensure all formwork components are installed according to the manufacturer’s specifications and guidelines.
• Conduct a thorough inspection of bracing systems before commencing work to confirm they are secure and correctly positioned.
• Utilise appropriate bracing materials that are suitable for the specific formwork system and load requirements.
• Implement regular checks and maintenance of bracing throughout the installation process to identify and rectify any issues promptly.
• Provide comprehensive training for workers on the correct methods of installing and securing bracing for formwork.
• Ensure that a competent person supervises the installation process to verify that all bracing is adequate and correctly installed.

Residual Risk: Minor (1) x Improbable (1) = Low (1)

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Inadequate Training and Supervision : Low (1)

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Who might be harmed: Construction workers | Site supervisors | Subcontractors | Apprentices

Type of harm: Back / Spinal Injury | Broken Bones | Crush / Entrapment | Cuts and Abrasions | Death | Electrocution | Head Injury | Muscular Injury

Initial Risk: Catastrophic (5) x Occasional (3) = Medium (15) Controls

• Ensure all personnel involved in formwork installation receive comprehensive training on safe work practises and procedures.
• Appoint a competent supervisor to oversee the installation process and ensure adherence to safety protocols.
• Conduct regular toolbox talks to reinforce safety awareness and address any concerns or questions.
• Implement a buddy system where experienced workers mentor less experienced colleagues during formwork installation.
• Regularly review and update training materials to reflect current best practises and regulatory requirements.

Residual Risk: Minor (1) x Improbable (1) = Low (1)

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Adverse Weather Conditions : Low (1)

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Who might be harmed: Construction workers | Site supervisors | Crane operators

Type of harm: Cold / Pneumonia | Death | Drowning | Heat Stroke / Exhaustion

Initial Risk: Severe (4) x Probable (4) = Medium (16) Controls

• Monitor weather forecasts and plan work schedules to avoid installation during adverse conditions such as heavy rain or strong winds.
• Ensure all formwork is securely braced and stabilised to withstand potential wind loads.
• Provide non-slip footwear and ensure walkways are clear to prevent slips on wet surfaces.
• Implement temporary covers or shelters to protect work areas from rain and reduce surface slipperiness.
• Train workers on recognising weather-related hazards and appropriate response actions.
• Suspend work if weather conditions deteriorate to a level that compromises safety.

Residual Risk: Minor (1) x Improbable (1) = Low (1)

COSHH Assessment : Installing Formwork

Form release agents

Form release agents are applied to formwork surfaces to facilitate the easy removal of the formwork from the cured concrete, preventing adhesion and ensuring a smooth finish.

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Inhalation : Low (1)

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Who might be harmed: Construction workers installing formwork | Site supervisors overseeing the installation | Nearby workers on the construction site

Type of harm: Respiratory damage / Asthma / COPD

Initial Risk: Catastrophic (5) x Frequent (5) = High (25) Controls

• Ensure adequate ventilation in the work area to disperse vapours.
• Use respiratory protective equipment (RPE) such as masks with appropriate filters.
• Limit the amount of form release agent used to the minimum necessary.
• Implement a safe work procedure for the application of form release agents.
• Conduct regular air monitoring to ensure exposure levels remain below occupational limits.
• Provide training on the safe handling and application of form release agents.

Residual Risk: Minor (1) x Improbable (1) = Low (1)

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Eye Contact : Low (1)

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Who might be harmed: Construction workers handling form release agents | Labourers assisting with formwork tasks

Type of harm: Eye Damage

Initial Risk: Catastrophic (5) x Frequent (5) = High (25) Controls

• Ensure workers wear safety goggles or face shields when applying form release agents.
• Provide training on the correct application techniques to minimise splashes and sprays.
• Use applicators with controlled spray nozzles to reduce the risk of splatter.
• Implement a safe distance protocol to keep unprotected personnel away during application.
• Ensure proper ventilation in enclosed spaces to prevent accumulation of airborne particles.

Residual Risk: Minor (1) x Improbable (1) = Low (1)

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Skin Contact : Low (1)

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Who might be harmed: Construction workers handling form release agents | Labourers assisting with formwork installation | Maintenance personnel cleaning equipment and tools

Type of harm: Dermatitis

Initial Risk: Major (3) x Frequent (5) = Medium (15) Controls

• Wear appropriate personal protective equipment, such as chemical-resistant gloves and long-sleeved clothing, to prevent direct skin contact with form release agents.
• Ensure proper training for workers on the safe handling and application of form release agents to minimise skin exposure.
• Implement a handwashing protocol with soap and water after handling form release agents to remove any residues from the skin.
• Provide safety data sheets and ensure workers are aware of the potential skin hazards associated with form release agents.
• Use barrier creams as an additional protective measure to reduce the risk of skin irritation from form release agents.

Residual Risk: Minor (1) x Improbable (1) = Low (1)

Concrete dust

Concrete dust is not an intended substance but rather a byproduct generated during the cutting, grinding, or drilling of concrete materials.

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Inhalation : Low (1)

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Who might be harmed: Construction workers installing formwork | Site supervisors and managers | Nearby workers on the construction site

Type of harm: Asbestosis / Lung Cancer / Mesothelioma | Respiratory damage / Asthma / COPD

Initial Risk: Severe (4) x Occasional (3) = Medium (12) Controls

• Use appropriate respiratory protective equipment (RPE) such as dust masks or respirators to prevent inhalation of concrete dust.
• Implement local exhaust ventilation systems to capture and remove airborne dust at the source.
• Dampen surfaces before cutting or drilling to minimise dust generation.
• Ensure regular maintenance and cleaning of work areas to reduce dust accumulation.
• Conduct work in well-ventilated areas to disperse airborne dust effectively.

Residual Risk: Minor (1) x Improbable (1) = Low (1)

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Eye Contact : Low (1)

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Who might be harmed: Construction workers installing formwork

Type of harm: Eye Damage

Initial Risk: Catastrophic (5) x Probable (4) = High (20) Controls

• Workers should wear safety goggles or face shields to prevent concrete dust from entering the eyes.
• Ensure that dust extraction systems are in place and functioning effectively to minimise airborne dust.
• Provide training on proper handling techniques to reduce dust generation during formwork installation.
• Implement wet cutting methods to suppress dust at the source.
• Maintain a clean work area by regularly removing accumulated dust with appropriate cleaning methods.

Residual Risk: Minor (1) x Improbable (1) = Low (1)

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Skin Contact : Low (1)

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Who might be harmed: Construction workers | Formwork installers | Labourers handling concrete materials

Type of harm: Dermatitis

Initial Risk: Catastrophic (5) x Probable (4) = High (20) Controls

• Wear long-sleeved clothing and gloves to minimise skin exposure to concrete dust.
• Use barrier creams to provide an additional protective layer on exposed skin.
• Wash skin thoroughly with soap and water after contact with concrete dust.
• Provide access to washing facilities with running water at the worksite.
• Implement regular cleaning schedules to reduce dust accumulation on surfaces.

Residual Risk: Minor (1) x Improbable (1) = Low (1)

Solvents from cleaning agents

Solvents used in cleaning agents are intended for the removal of residues and build-up from tools and equipment to maintain their functionality and safety.

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Inhalation : Low (1)

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Who might be harmed: Construction workers installing formwork | Site supervisors overseeing the work | Nearby workers on the construction site

Type of harm: Asphyxia | Respiratory damage / Asthma / COPD | Illness | Death

Initial Risk: Major (3) x Occasional (3) = Medium (9) Controls

• Ensure adequate ventilation in the work area to disperse solvent vapours.
• Use appropriate respiratory protective equipment, such as masks or respirators, when necessary.
• Limit the duration of exposure by scheduling regular breaks away from the work area.
• Store solvents in tightly sealed containers when not in use to prevent vapour release.
• Implement a solvent substitution programme to use less hazardous alternatives where possible.

Residual Risk: Minor (1) x Improbable (1) = Low (1)

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Eye Contact : Low (1)

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Who might be harmed: Construction workers handling cleaning agents

Type of harm: Eye Damage

Initial Risk: Major (3) x Frequent (5) = Medium (15) Controls

• Ensure workers wear safety goggles or face shields when handling solvents.
• Provide training on the proper use and handling of cleaning agents.
• Implement proper storage procedures to prevent accidental spills or splashes.
• Ensure adequate ventilation in areas where solvents are used.
• Provide access to eye wash stations in close proximity to work areas.

Residual Risk: Minor (1) x Improbable (1) = Low (1)

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Skin Contact : Low (1)

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Who might be harmed: Construction workers handling cleaning agents | Maintenance personnel cleaning tools and equipment

Type of harm: Burns | Dermatitis

Initial Risk: Major (3) x Occasional (3) = Medium (9) Controls

• Wear appropriate chemical-resistant gloves to prevent direct skin exposure.
• Use long-sleeved clothing to minimise skin contact with solvents.
• Ensure proper ventilation to reduce solvent concentration in the work area.
• Provide washing facilities with soap and water for immediate decontamination.
• Implement training on safe handling and use of solvents to prevent skin exposure.

Residual Risk: Minor (1) x Improbable (1) = Low (1)

Toolbox Talk : Installing Formwork

Introduction

The installation of formwork for slabs, walls, and beams involves the assembly of proprietary shuttering panels or pans, supplemented by timber formwork components, to create a mould into which concrete is poured. This process is fundamental in providing the necessary shape and support for concrete structures during the curing phase. The primary aim of this task is to ensure that the formwork is constructed accurately and securely, maintaining structural integrity and alignment, while adhering to design specifications. Proper installation is crucial to prevent structural failures and ensure the safety of all personnel involved in the construction process.

Hazards

The installation of formwork for slabs, walls, and beams presents several significant hazards. Working at height poses a risk of falls, which can result in serious injury or fatality. Manual handling of heavy panels and timber components can lead to musculoskeletal injuries. There is a danger of being struck by falling objects, such as tools or materials, from above. Exposure to hazardous substances, such as form release agents, can cause skin irritation or respiratory issues. Electrical hazards may arise from the use of power tools. Uneven surfaces increase the risk of trips and slips. Collapsing formwork can cause crushing injuries, while inadequate bracing may lead to structural instability. Insufficient training and supervision can result in unsafe practises, and adverse weather conditions can exacerbate these risks by creating slippery surfaces or affecting the stability of the formwork.

Installing Formwork : Rules

• Do conduct a thorough risk assessment prior to commencing work.
• Do ensure all personnel are adequately trained and competent in formwork installation.
• Do wear appropriate personal protective equipment (PPE), including hard hats, safety boots, gloves, and high-visibility clothing.
• Do inspect all formwork materials and equipment for damage or defects before use.
• Do ensure that the work area is clean, organised, and free from trip hazards.
• Do use proper lifting techniques and equipment to handle heavy materials safely.
• Do secure all tools and materials to prevent them from falling.
• Do ensure that formwork is adequately braced and supported to prevent collapse.
• Do follow manufacturer’s instructions for the assembly and installation of proprietary shuttering panels.
• Do communicate effectively with team members and supervisors to ensure safe working practises.
• Do monitor weather conditions and adjust work plans accordingly to maintain safety.
• Do ensure that all electrical tools are properly maintained and used in accordance with safety guidelines.
• Do establish clear access routes and emergency exits in the work area.
• Do report any hazards, incidents, or near misses to a supervisor immediately.

Installing Formwork : Warnings

• Do not commence work without a thorough risk assessment and method statement.
• Do not proceed without appropriate personal protective equipment (PPE), such as hard hats, gloves, and safety boots.
• Do not work at height without proper fall protection measures in place.
• Do not lift or move heavy components without assistance or mechanical aids.
• Do not stand or walk under suspended loads.
• Do not use damaged or defective formwork components.
• Do not ignore manufacturer’s instructions for proprietary systems.
• Do not leave tools or materials in walkways, creating trip hazards.
• Do not use power tools without ensuring they are in good working condition and properly grounded.
• Do not work in adverse weather conditions that may compromise safety.
• Do not alter or remove bracing without proper assessment and approval.
• Do not allow untrained personnel to install or dismantle formwork.
• Do not neglect to secure formwork against wind or other environmental factors.
• Do not rush the installation process, compromising safety for speed.

Induction Record

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Location:		Contract No:

Subject:	Risk Assessment and Method Statement : Installing Formwork	Tutor:
Date:		Signature:

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