Method Statement : Installing Soffit Formwork System

Explanation

The installation of a soffit formwork system for elevated slabs involves the precise assembly of proprietary shuttering panels or pans, which are supported by upright supports or a system scaffold. This process is critical in providing a stable and secure mould for concrete pouring, ensuring the structural integrity of the slab. The task requires additional scaffolding around the perimeter to facilitate safe access and movement, as well as the installation of upstands at slab edges to contain the concrete. The primary aim of this operation is to create a robust and level surface that meets design specifications while adhering to stringent health and safety standards.

Responsibilities

• Site Manager: Ensure overall compliance with health and safety regulations and oversee the installation process.
• Supervisor: Coordinate the installation team and ensure adherence to the Safe Operating Procedure.
• Formwork Installer: Assemble and install the soffit formwork system according to the manufacturer’s instructions and safety guidelines.
• Scaffold Erector: Install and secure additional scaffolding around the perimeter to provide safe access and working platforms.
• Health and Safety Officer: Conduct risk assessments and monitor safety practises during the installation process.
• Equipment Operator: Operate machinery and tools safely, ensuring they are in good working condition.
• Labourer: Assist with manual handling tasks and maintain a clean and organised work area.

Equipment

• Hammer
• Spirit level
• Tape measure
• Adjustable wrench
• Screwdriver set
• Power drill
• Circular saw
• Lifting equipment
• Scaffolding components
• Shuttering panels/pans
• Upright supports
• Hard hat
• Safety goggles
• High-visibility vest
• Safety gloves
• Steel-toe boots
• Hearing protection
• Fall arrest harness

Operation

• Conduct a risk assessment to identify potential hazards and implement control measures.
• Ensure all personnel involved are trained and competent in the installation of soffit formwork systems.
• Verify that all necessary personal protective equipment (PPE) is available and in good condition.
• Inspect all formwork components and scaffolding for damage or defects prior to use.
• Confirm that the work area is clear of obstructions and debris.
• Ensure that a safe access and egress route is established for workers.
• Check that the ground conditions are stable and suitable for supporting the formwork system.
• Review and communicate the emergency procedures to all personnel involved in the task.
• Ensure that all tools and equipment required for the installation are available and in proper working order.
• Coordinate with relevant parties to ensure that overhead power lines are de-energised or adequately protected.
• Establish a communication plan for the team, including hand signals or radios if necessary.
• Verify that weather conditions are suitable for safe installation activities.
• Erect perimeter scaffold around the slab edges, ensuring it is securely anchored and stable.
• Position and secure upright supports or system scaffold at designated locations, ensuring they are plumb and stable.
• Carefully lift and position proprietary shuttering panels or pans onto the upright supports, ensuring they are aligned correctly and securely fastened.
• Install upstands at slab edges, ensuring they are securely fixed and aligned with the formwork system.
• Inspect the entire formwork system for proper alignment and stability, making any necessary adjustments.
• Perform a thorough safety inspection of the installed formwork system, checking for any potential hazards or deficiencies.
• Brief the team on the completed installation, highlighting any specific safety considerations or areas requiring attention during subsequent work activities.

Risk Assessment : Installing Soffit Formwork System

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

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

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

• Ensure all personnel are trained in working at height procedures and the use of fall protection equipment.
• Utilise guardrails and toe boards on scaffolding and elevated platforms to prevent falls.
• Implement a fall arrest system, such as safety harnesses and lanyards, for workers operating at height.
• Conduct a risk assessment prior to commencing work to identify potential hazards and implement appropriate controls.
• Regularly inspect scaffolding and formwork systems for stability and integrity before use.
• Ensure that access ladders are securely fixed and extend at least one metre above the landing point.
• Maintain clear communication among team members to coordinate movements and ensure safety.
• Limit the number of workers on elevated platforms to prevent overloading and maintain stability.

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

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Manual handling : Low (1)

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

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

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

• Ensure all personnel are trained in proper lifting techniques and manual handling procedures specific to formwork components.
• Utilise mechanical aids, such as hoists or forklifts, to lift and position heavy formwork panels and supports.
• Plan the layout of the work area to minimise the distance that materials need to be manually transported.
• Assign sufficient personnel to tasks involving heavy lifting to distribute the load and reduce strain.
• Conduct a risk assessment prior to commencing work to identify potential manual handling hazards and implement appropriate controls.
• Encourage regular breaks and rotation of tasks to prevent fatigue and reduce the risk of musculoskeletal injuries.

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

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Struck by objects : Low (1)

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

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 Occasional (3) = Medium (12) Controls

• Ensure all tools and materials are securely fastened when working at height to prevent them from falling.
• Erect barriers or netting around the work area to catch any falling objects and protect workers below.
• Implement a clear exclusion zone beneath the work area to prevent unauthorised access during installation.
• Use tool lanyards to secure hand tools when working on elevated platforms or scaffolding.
• Conduct regular inspections of the formwork system to ensure stability and prevent accidental dislodgement of components.
• Provide workers with appropriate personal protective equipment, such as hard hats, to mitigate injury from falling objects.
• Ensure proper communication and coordination among team members to avoid accidental dislodgement of materials.

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

Type of harm: Burns | Death | Electrocution

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

• Ensure all electrical installations and equipment are inspected and tested by a qualified electrician before commencing work.
• Maintain a safe distance from overhead power lines by using non-conductive tools and equipment.
• Implement a lockout/tagout system to ensure that electrical circuits are de-energised before work begins.
• Provide workers with appropriate personal protective equipment, such as insulated gloves and footwear.
• Conduct regular safety briefings to raise awareness of electrical hazards and safe working practises.
• Use ground-fault circuit interrupters (GFCIs) on all temporary electrical installations to prevent electric shock.
• Clearly mark and secure all electrical hazards in the work area to prevent accidental contact.

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

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Structural collapse : Low (1)

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

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

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

• Ensure all formwork components are inspected for damage or defects prior to installation to prevent structural failure.
• Use only trained and competent personnel to assemble and install the soffit formwork system according to the manufacturer’s guidelines.
• Implement a system of regular inspections and maintenance checks on the formwork during the installation process.
• Ensure that the load capacity of the formwork system is not exceeded by accurately calculating and distributing loads.
• Utilise appropriate bracing and support systems to maintain stability and prevent collapse during installation.
• Establish a clear communication protocol among workers to promptly address any signs of instability or potential collapse.
• Ensure that all temporary supports and scaffolding are correctly installed and secured to provide adequate support to the formwork.

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

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Slips, trips, and falls : Low (1)

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

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

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

• Ensure all work areas are kept clean and free from debris to prevent tripping hazards.
• Use non-slip footwear to provide better traction on potentially slippery surfaces.
• Install temporary lighting to improve visibility in dimly lit areas and reduce the risk of trips.
• Clearly mark and secure any uneven surfaces or changes in level to alert workers.
• Regularly inspect and maintain scaffolding and platforms to ensure they are stable and secure.
• Implement a housekeeping schedule to routinely check and address potential slip and trip hazards.

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

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Noise exposure : Low (1)

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Who might be harmed: Construction workers directly involved in the installation process | Site supervisors overseeing the work | Nearby workers on the construction site

Type of harm: Permanent Hearing Damage

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

• Provide workers with appropriate hearing protection, such as earplugs or earmuffs, and ensure they are worn at all times during noisy operations.
• Schedule noisy tasks during times when fewer workers are present to minimise overall exposure.
• Regularly maintain and service machinery and tools to ensure they operate as quietly as possible.
• Implement a noise monitoring programme to assess and document noise levels in the work area.
• Erect noise barriers or screens around particularly loud equipment to reduce noise transmission.
• Conduct training sessions for workers on the risks of noise exposure and the proper use of hearing protection.

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

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Hazardous substances : Low (1)

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Who might be harmed: Construction workers directly involved in the installation process. | Site supervisors overseeing the work. | Nearby workers on the construction site.

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

Initial Risk: Severe (4) x Frequent (5) = High (20) Controls

• Ensure all workers are provided with and wear appropriate personal protective equipment, such as gloves and masks, when handling hazardous substances.
• Implement proper storage procedures for hazardous substances to prevent accidental spills or leaks.
• Provide training for workers on the safe handling and use of hazardous substances specific to the installation process.
• Ensure that safety data sheets for all hazardous substances are readily accessible to all workers on site.
• Establish a clear protocol for the immediate clean-up and disposal of any spills or leaks of hazardous substances.
• Ensure adequate ventilation in areas where hazardous substances are used to prevent the accumulation of harmful vapours.

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

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Inadequate lighting : Low (1)

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

Type of harm: Back / Spinal Injury | Broken Bones | Cuts and Abrasions | Head Injury | Multiple / Various Injury

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

• Ensure adequate temporary lighting is installed at the worksite to illuminate all areas where soffit formwork is being installed.
• Conduct regular inspections of lighting equipment to ensure it is functioning correctly and replace any faulty units immediately.
• Position lighting to minimise shadows and glare that could obscure vision or create hazards during installation.
• Provide portable lighting solutions for workers to use in areas where fixed lighting is insufficient.
• Schedule work during daylight hours whenever possible to maximise natural light availability.

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

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Weather conditions : Low (1)

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Who might be harmed: Construction workers | Scaffolders | Crane operators

Type of harm: Cold / Pneumonia | Heat Stroke / Exhaustion | Illness

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

• Monitor weather forecasts regularly and plan work schedules to avoid adverse weather conditions such as high winds or heavy rain.
• Ensure that all workers are equipped with appropriate personal protective equipment, including waterproof clothing and non-slip footwear, to mitigate the effects of wet conditions.
• Secure all formwork components and materials to prevent them from being dislodged by strong winds.
• Implement temporary weather protection measures, such as tarpaulins or shelters, to shield the work area from rain or excessive sun exposure.
• Establish clear communication protocols for halting work and evacuating the site safely in the event of sudden severe weather changes.

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

COSHH Assessment : Installing Soffit Formwork System

Concrete dust

Concrete dust is not intentionally used but is generated as a by-product during cutting, drilling, or surface preparation of concrete elements.

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Inhalation : Low (1)

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Who might be harmed: Construction workers installing the formwork | Site supervisors and managers | Nearby tradespeople working in adjacent areas

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

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

• Use water suppression systems to dampen concrete dust during cutting or drilling.
• Provide workers with appropriate respiratory protective equipment, such as N95 masks.
• Implement local exhaust ventilation systems to capture dust at the source.
• Conduct regular air monitoring to ensure dust levels remain below occupational exposure limits.
• Train workers on proper techniques to minimise dust generation during tasks.
• Establish designated cutting areas with barriers to contain dust spread.

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 the formwork | Site supervisors overseeing the installation | Nearby workers on the construction site

Type of harm: Eye Damage

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

• Wear safety goggles or face shields to prevent dust from entering the eyes.
• Use water suppression methods to minimise airborne dust during cutting or drilling.
• Implement local exhaust ventilation systems to capture dust at the source.
• Ensure proper housekeeping to reduce dust accumulation in the work area.
• Provide training on the correct use of personal protective equipment (PPE).

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 formwork components | Labourers involved in mixing or pouring concrete

Type of harm: Dermatitis

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

• Workers should wear long-sleeved clothing and gloves to minimise skin exposure to concrete dust.
• Barrier creams should be applied to exposed skin areas before work commences.
• Provide washing facilities with soap and water for workers to clean skin regularly.
• Ensure workers are trained on the importance of personal hygiene and protective equipment use.

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

Formwork release agents

Formwork 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 handling formwork release agents | 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 appropriate respiratory protective equipment, such as masks or respirators, when applying release agents.
• Limit the amount of formwork release agent used to the minimum necessary for the task.
• Implement a no-smoking policy in areas where formwork release agents are used.
• Conduct regular air monitoring to ensure vapour levels remain below occupational exposure limits.

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 formwork components

Type of harm: Eye Damage

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

• Ensure workers wear safety goggles or face shields when handling formwork release agents.
• Provide training on the proper application techniques to minimise splashes and spills.
• Implement a designated area for mixing and applying release agents, away from other activities.
• Ensure availability of eye wash stations in close proximity to work areas.
• Conduct regular inspections to ensure personal protective equipment is used correctly.

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 formwork components | Labourers assisting with formwork setup

Type of harm: Dermatitis

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

• Wear appropriate personal protective equipment, such as chemical-resistant gloves, to prevent direct skin contact with formwork release agents.
• Ensure that all workers are trained in the safe handling and application of formwork release agents, including the importance of avoiding skin contact.
• Provide washing facilities with soap and water nearby for immediate decontamination in case of accidental skin exposure.
• Implement a system for regular inspection and maintenance of personal protective equipment to ensure its effectiveness.
• Use long-handled tools or applicators to minimise direct handling of formwork release agents.

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

Toolbox Talk : Installing Soffit Formwork System

Introduction

The installation of a soffit formwork system for elevated slabs involves the precise assembly of proprietary shuttering panels or pans, which are supported by upright supports or a system scaffold. This process is critical in providing a stable and secure mould for concrete pouring, ensuring the structural integrity of the slab. The task requires additional scaffolding around the perimeter to facilitate safe access and movement, as well as the installation of upstands at slab edges to contain the concrete. The primary aim of this operation is to create a robust and level surface that meets design specifications while adhering to stringent health and safety standards.

Hazards

The installation of soffit formwork systems for elevated slabs presents several significant hazards. Working at height poses a risk of falls, necessitating the use of appropriate fall protection measures. Manual handling of heavy shuttering panels and upright supports can lead to musculoskeletal injuries if not managed correctly. There is a danger of being struck by falling objects, particularly during the placement of panels and scaffold components. Electrical hazards are present if work is conducted near overhead power lines, requiring vigilance and adherence to safe distances. The potential for structural collapse exists if the formwork system is not properly installed or supported, posing a severe risk to workers. Slips, trips, and falls may occur on wet or uneven surfaces, especially around the perimeter where additional scaffolding is installed. Noise exposure from machinery and tools used during installation can affect hearing if not adequately controlled. Lastly, contact with hazardous substances, such as chemicals used in the process, must be managed to prevent health risks.

Installing Soffit Formwork System : Rules

• Do conduct a thorough risk assessment prior to commencing work.
• Do ensure all personnel are trained and competent in formwork installation.
• Do wear appropriate personal protective equipment (PPE) at all times, including hard hats, safety boots, gloves, and high-visibility clothing.
• Do inspect all equipment and materials for defects before use.
• Do secure all tools and materials to prevent them from falling.
• Do use proper lifting techniques and equipment to handle heavy components.
• Do maintain clear communication among team members, especially when working at height.
• Do ensure that scaffolding and supports are correctly erected and stable.
• Do follow manufacturer’s instructions for the assembly and installation of the formwork system.
• Do establish exclusion zones to keep unauthorised personnel away from the work area.
• Do regularly inspect the formwork system during installation for signs of instability or damage.
• Do ensure that all electrical hazards are identified and controlled, including maintaining safe distances from power lines.
• Do keep the work area tidy and free from obstructions to prevent slips, trips, and falls.
• Do monitor noise levels and use hearing protection if necessary.
• Do report any incidents or near misses immediately to a supervisor.

Installing Soffit Formwork System : Warnings

• Do not commence work without a thorough risk assessment and method statement.
• Do not proceed without proper training and understanding of the formwork system.
• Do not work at height without appropriate fall protection measures in place.
• Do not lift heavy components without using correct manual handling techniques or mechanical aids.
• Do not stand or walk under suspended loads.
• Do not use damaged or defective formwork components or equipment.
• Do not ignore the need for personal protective equipment, such as hard hats, gloves, and safety boots.
• Do not work near overhead power lines without ensuring safe clearance.
• Do not leave tools or materials unsecured on elevated platforms.
• Do not alter or remove any safety barriers or guardrails without authorisation.
• Do not work in adverse weather conditions that could compromise safety.
• Do not neglect to inspect the formwork system regularly for stability and integrity.

Induction Record

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