2008 Edition
FORMWORK
Health and Safety
Developed by trade labour-management health and safety committees, this manual is fully a
document of accord between labour and management authorities.
In the past, members of the public have used printed information that was outdated by subsequent
improvements in knowledge and technology. We therefore make the following statement for their
protection in the future.
The information presented here is, to the best of our knowledge, current at time of printing
and is intended for general application. This publication is not a definitive guide to government
regulations or to practices and procedures wholly applicable under every circumstance. The
appropriate regulations and statutes should be consulted. Although the Construction Safety
Association of Ontario cannot guarantee the accuracy of, nor assume liability for, the information
presented here, we are pleased to answer individual requests for counselling and advice.
Labour-Management
The Construction Safety Association of Ontario (CSAO) thanks the members of the Labour-
Management Health and Safety Committees who contributed their knowledge, experience, and time
in preparing this manual. In particular, CSAO thanks the members of the Carpenters Trade Labour-
Management Health and Safety Committee and the High-Rise Forming Sector Labour-Management
Health and Safety Committee for their work to develop this manual.
ISBN-13: 978-1-894761-06-2
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CONTENTS
SITE PREPARATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1. The work area: excavation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
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ASSEMBLY ....................................................................... 17
1. Health hazards related to formwork assembly/preparation ...................... 18
Sawdust: respiratory hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Form oil: respiratory and other health hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Prevention . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Physical hazards associated with reinforcing steel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
5. Waterstop ......................................................................... 38
Health hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Physical hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
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3. Ties ............................................................................... 45
Strength of ties . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Inspection before pouring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Layout and installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Types of ties . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
CONCRETE ....................................................................... 49
1. Preparation before placing concrete ............................................. 50
Being prepared . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Cleaning out, de-icing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Location of equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
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3. Placing concrete . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Before pouring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Pour rate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Conveyances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
4. Consolidation ..................................................................... 55
Proper use of vibrator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Size of vibrator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Consolidation techniques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Depth of consolidation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Electrical hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
5. Finishing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Ventilation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Guards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Other hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
3. Flyforms .......................................................................... 64
SUMMARY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
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SITE
PREPARATION
1
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BARRIERS
If an excavation is more than 2.4 metres deep
and the banks are not sloped, a barrier,
equivalent to a guardrail, of at least 1.1 metres
high must be erected.
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WATER CONTROL
3) WATER CONTROL
RISKS RELATING TO container. Do not decant or refill fuel
STANDING WATER tanks near or over a body of water.
Always handle fuel in a controlled
Standing water must be removed and contained area to prevent any
before work begins, and environmental contamination.
regularly as it accumulates. Exhaust fumes from the engine can be
Water left in the excavation can turn deadly, so make sure the pump is set
solid soil to unstable mud. Mud is up in an open, well-ventilated area.
hazardous for workers and can seriously Ensure that the fumes are not collecting
endanger the stability of the formwork at the bottom of a trench or excavation.
and structural integrity of the building. If there isnt enough air movement to
Standing water becomes ice in cold prevent this, set up fans or keep
weather. Ice on the ground greatly workers out.
increases the risk of slips and falls.
Water should be drained before it
freezes, or if necessary, ice should be
CONTROL AND DIVERSION OF WATER
shoveled up and removed. Water seeping and migrating from the
Standing water provides a place for banks of the excavation can have a
mosquitoes to breed. Mosquitoes can serious effect on the stability of the soil.
carry West Nile Virus, a serious health It endangers the lives of workers by
risk. To decrease the risk of West Nile decreasing soil stability and increasing
Virus, remove standing water whenever the chance of a cave-in. You must
it accumulates. The site should be address this problem.
graded to prevent the accumulation Running water must be diverted from
of standing water. the banks of the excavation to prevent
the erosion of soil that can lead to cave-
ins. Even small amounts of running
DRAINAGE/PUMPING WATER water can erode and undermine
A pump and discharge hose used to footings, which can lead to instability
transfer water out of the work area can and collapse of formwork. You must
be heavy and awkward to carry, divert any water away from formwork
especially on a wet, muddy site. To and footings until a permanent weeping
reduce the risk of overexertion, separate system is in place and functioning.
the pump and hose and move them one If water infiltrates the form before the
at a time to the work area. concrete has set, it can wash out the
For gasoline-powered pumps, store and cement and seriously weaken the
transport fuel only in an approved
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WATER CONTROL
ELECTRICAL HAZARDS
There is a high risk of electrical shock
when extension cords and electric hand
tools are used in wet areas.
Extension cords must not be run
through waterthey must be kept in
dry locations to minimize the risk of
shock.
You must have ground fault circuit
interrupter (GFCI) outlets when using
electrical equipment outdoors.
Cord casings must be free of cracks or
other visible damage, and plugs must
have all three prongs intact and be
securely attached to cords.
Electric hand tools must have ground
prongs intact on their plugs OR be
double-insulated.
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CONFINED SPACES
4) CONFINED SPACES
Confined spaces can be deadly, so it is very result in acute health effects that
important to read and understand all the pose an immediate threat to life,
requirements of the Construction Regulation or
relating to them. The following information interfere with a persons ability
is a brief summary, but must not be to escape unaided from a
considered a comprehensive guide for confined space.
working in a confined space. For more Atmospheric hazards can be caused
information, refer to the Construction by such things as engine exhaust,
Regulation and also to the chapter on welding fumes, form-oil (or other
confined spaces in the Construction Safety chemical) vapours, methane leaking
Association of Ontarios Construction Health from a damaged sewage pipe, and
and Safety Manual (M029). Both documents natural gas or propane leaking from
are available on www.csao.org. a damaged supply line.
Confined spaces can harbour a number
RECOGNIZING POTENTIAL HAZARDS of hazards which can pose serious
threats to workers. Along with the
A confined space exists in an area potential for atmospheric hazards,
that is either fully or partially there can be physical hazards. These
enclosed, hazards may cause injury or increase
that is not both designed and the severity of an injury caused by
constructed for continuous human other means.
occupancy, and Examples of physical hazards are
in which atmospheric hazards may noise
occur because of its construction, temperature
location, or contents, or because of
radiation (welding, x-rays)
work that is done in it.
cramped working spaces
Atmospheric hazards means
reactive or corrosive residues
(a) the accumulation of flammable,
poor means of entry and exit
combustible, or explosive agents, or
rotating or moving equipment
(b) an oxygen content in the
electrical hazards
atmosphere that is less than
19.5 percent or more than uncontrolled movement of liquids
23 percent by volume, or and solids
(c) the accumulation of atmospheric vibration.
contaminants, including gases, Inside a confined space, physical
vapours, fumes, dusts, or mists, hazards often involve a greater risk and
that could severity of potential injury than they do
outside a confined space.
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CONFINED SPACES
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MATERIAL
HANDLING
11
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Column 1 Column 2
If site space is limited and form panels
Nominal phase-to-phase Minimum
must be stored on the banks of the voltage rating distance
excavation, you must take steps to keep 750 to 150,000 volts 3 metres
them secure and prevent them from
more than 150,000 to
sliding. A combination of stakes, braces, 4.5 metres
250,000 volts
ropes, straps, and other restraints can all more than 250,000 volts 6 metres
be used to keep panels from moving.
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If powerlines present a risk, take the proper steps to ensure protection of workers.
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TRAINING
REQUIREMENTS
Written proof that a worker
is trained in the safe
operation of a crane, boom
truck, forklift, or similar
lifting or hoisting device is
required.
This hydraulic jack is used to help place and level fly forms.
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HAZARDS
Your sight lines can be
You often need two people to carry something safely over uneven
reduced when carrying plywood and surfaces or with awkward objects.
other sheet materials, so be very
sure that your path is clear. Be aware
of the location and path of travel of
vehicles, equipment, and other workers.
Plywood and other sheet materials can
be difficult to handle in the wind. The
added and unexpected extra load
imposed by a sudden gust of wind can
throw a worker off-balance and lead to
a fall. In windy conditions, get help
when carrying or moving sheet
materials.
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ASSEMBLY
17
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CONSTRUCTING FORMS
2) CONSTRUCTING FORMS
SLAB, WALL, AND COLUMN FORMS structure. Since each floor is the same,
virtually no changes need to be made to the
The main health and safety concerns during
form from one pour to the next. This method
the formwork construction phase are related
increases production over traditional built-in-
to
place frame-supported forming. It also
general material handling and lifting
improves overall safety of the forming
cutting and connecting lumber and operation by minimizing or eliminating the
metal amount and type of heavy material handling
falling from heights. associated with built-in-place methods.
Since much of the material needed for There are three common types of flying
forming can be supplied to the work area forms:
by crane, hoisting and rigging safety is very
important, as is worker awareness of the Deck-on-truss suspended slab forms.
hazards of overhead loads. Large metal trussesusually aluminum
because of its light weightare spanned
For more information, see Types of by joists, which are in turn covered with
Formwork in the Formwork section of the sheathing to accept the concrete.
Construction Safety Association of Ontarios
Construction Health and Safety Manual The trusses are commonly 1.5 to
(M029), which you can download free from 2 metres deep, and whatever length
www.csao.org. necessary to suit the project. The
underside of the trusses has a series of
1) FLYING FORMS shores or jacks that rest on a previously-
poured section of slab. They allow the
Flying forms are large sections of formwork,
flying form to be raised and leveled into
often including trusses, beams, shoring
the correct position for the pour.
towers, braces, and other support
mechanisms that are moved from one
Column/wall supported slab forms.
location to another. Although the term can
Wide-flange beams are spanned by
be applied to any form that is moved by
joists, which are in turn covered with
crane (or other hoisting device) to multiple
sheathing to create this flying form.
locations, it is most commonly used to
describe a unit of typical suspended slab
The beams are supported by hardware
formwork.
mounted to columns and walls from the
previous pour, without the need for
Flying forms are most often used on the
vertical shores or jacks. The hardware
typical floors of a reinforced concrete
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CONSTRUCTING FORMS
allows for the suspended slab form Much like gang forms, the size of a section
to be positioned correctly, and then of fly form is often only limited by the lifting
provides adequate support for the capacity of the sites crane. The fly form is
placement of reinforcing steel and built slightly narrower in span than the
concrete. distance between demising partitions or rows
of columns in the typical location it will be
Deck-on-frame suspended slab used. Once it is in place and leveled, you
forms. install filler strips to make the formwork
Shoring towers or posts are used to continuous.
support a conventionally-built
suspended slab form, and are fastened Regardless of the type of fly form, all are
together to make an integrated unit. designed to be lowered in place once the
The vertical shores have jacks to allow concrete has had time to set. Once lowered,
the formwork to be leveled correctly, the form is pushed, often on rollers, out past
and the bases are attached to a the edge of the supporting slab, and it is
continuous ledger that sits directly on attached to the crane as it emerges. When
the previously-poured slab to disperse it is fully supported by the crane and free
the load. of the building, it is hoisted to the next level
where the process is repeated.
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CONSTRUCTING FORMS
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CONSTRUCTING FORMS
3) GANG FORMS
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CONSTRUCTING FORMS
itself. Since gang forms can be used for Avoid climbing the panels, especially during
continuous sections of exterior walls, the placement and connection phase when
workers often find themselves high above the panels are not secure enough to resist
the ground as construction progresses. shifting in place or falling over.
You must have proper guardrails on the
platforms, and there must be a safe means of Stay clear of joints when panels are being
getting on and off the platforms. In addition, set together. Being pinched in between two
while the formwork is supported or panels can lead to serious injuries. Also,
stabilized by the crane, each worker on the if panels are to be placed by workers
platform must use a fall-arrest system
including an anchor point which is
independent of the formwork.
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CONSTRUCTING FORMS
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CONSTRUCTING FORMS
Closing in at least two sides of the work area form exposes a worker to a fall, then you
can also improve safety. Wind can make it must have fall protection methods in place.
difficult and dangerous to carry material, Proper training, along with equipment such
especially sheet material such as plywood. as scaffolds, guardrails, harnesses, and
It can lead to overexertion injuries, slips, lanyards must be provided and used.
and falls. Wind can also shift material on
the cutting table, causing a saw to bind or Choose the right storage space for incoming
kick back, causing broken bones, contusions, forming material. Ideally, the storage area
or amputations. should be easily accessible by delivery
vehicles so that material can be unloaded
Wind can also blow around sawdust, and stored with the least number of
shavings, and wood particles. When these intermediate steps. The more time workers
particles get in your eyes, they can cause eye have to spend physically handling the
injuries. They can also lead to other serious material, the greater the risk of overexertion
physical injuries when you become and repetitive strain injuries.
disoriented by sudden vision impairment.
Use walls or tarps to block the wind in Likewise, the storage area should be close to
the shop area. It will be more difficult for the shop to minimize intermediate handling.
dust and debris to become airborne. Reduce Material storage should be easily accessible
the amount of material that can become from both the cutting area and the assembly
airborne by using saws fitted with dust area of the shop. After assembly, the
extractors and by cleaning up the shop completed form sections should go to a
area regularly. staging area. From there, they can be
delivered to the erection site. Depending on
Accumulated sawdust, wood shavings, the nature of the project, forms may be
scraps, and general clutter not only slow delivered by hand, on carts, dollies, or
down production, but they also present vehicles, or by crane.
a fire hazard. Keep the shop area clean.
Aluminum and steel can be used to varying
Even if your shop area is perfectly clean, degrees in formwork. Aluminum beams are
the Construction Regulation requires that you often used as wales in place of lumber.
have adequate fire extinguishers or other fire Aluminum, when manufactured into wide-
protection systems in place. See the Fire flange beams, has a very high strength-to-
Safety chapter of the Construction weight ratio, making it easy to carry and
Regulation. place. Aluminum beams are durable and
arent susceptible to rot or decay. Unless an
Give thought to fall protection in the shop aluminum beam is damaged by a drop or
area. Workers constructing a form can be impact, it will not warp or twist as lumber
exposed to a fall even if the form is nowhere does when exposed to the environmental
near its final destination. If constructing a conditions of a jobsite.
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CONSTRUCTING FORMS
Metal can also be used for studs, struts, Pressure increases as the height of the form
sheathing, and complete panels. The main increases, but not as width increases. This
concern with metal components is their makes the concrete mix design as important
weight. Formwork sectionsand often even as the formwork design itself. Concrete
individual panelscan be too heavy to be slump and admixtures are factors that
placed by hand so you have to use a crane determine the rate of curing, and the rate of
or other suitable hoisting device. Safe curing controls the pour rate that the
hoisting and rigging procedures must be formwork is designed to withstand. So never
understood and followed whenever any make changes to the concrete mixsuch as
hoisting device is used. adding water on sitewithout the engineers
approval.
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CONSTRUCTING FORMS
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CONSTRUCTING FORMS
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CONSTRUCTING FORMS
fasteners can be removed and re-used, and effort, so you also need solid footing.
the protruding ties broken off and discarded Scaffoldingeither self-standing or hanging
to make it easier to remove the forms. When bracketis the safest choice for a work
you break off ties, ensure that no portion of platform. To protect workers exposed to a
the tie is protruding from the concrete in a fall, guardrails or personal fall protection
way that could injure a worker. The edges must also be provided and used.
of a broken tie can be extremely sharp.
Use the proper strength and type of ties
If the ties do protrude out of the concrete, for the project. This information will be
they must be cut off flush with the face of specified in engineers design drawings
the concrete to prevent workers from being for formwork. Mixing up ties can confuse
scratched, cut, impaled, or otherwise injured workers, leading to installation errors
in the event of contact. and ultimately form failure. Ensure that
all ties used within any form are of the same
strength, size, and type.
Medium and heavy forming
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CONSTRUCTING FORMS
be identical. Since the floor plan repeats You may need a scaffold or ladder, set up in
itself, it is possible to use the same a safe manner, to connect and disconnect
formwork in the same area over and over. hoist lines to the top of wall, column, or
However, regardless of how many typical other forms. Likewise, guardrails or personal
floors are being built, it is extremely fall protection may be required for fly forms
important to follow the engineered or any other panel or slab system that
drawings during assembly and the requires a worker to be near an open edge
inspection procedures prior to concrete at height. Climbing the braces, wales, or any
placement. other part of the formwork or falsework is
unsafe, and should not be done to connect
The information provided in engineered or disconnect hoisting linesor for any other
drawings and details must be followed. Any reason.
variation from the quality or quantity of ties,
supports, braces, accessories, etc., can lead
to formwork failure and worker injury or
death. To prevent such incidents, variations
must be approved by the professional
engineer responsible for the form design.
See Sections 31 and 87- 92 of the Construction
Regulation.
ATTACHMENT POINTS ON
FORMWORK
You must give careful consideration to the A lift point must be designed and built as
placement of, and connection to, attachment part of a form panel.
points on form panels. They must be shown
on the design drawings. The lift points must
be able to support the total load applied
when the form is lifted. They must also be
located in places such that the worker who
is connecting and disconnecting hoist lines
to them is not endangered. The lift points
must keep the panel stable so that it stays in
the proper plane while it is being hoisted.
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OILING FORMWORK
3) OILING FORMWORK
TIMING OF APPLICATION FIRE HAZARD
Generally, a form-release coating (form oil) Some form oils are flammable. Refer to the
is applied when construction of the form is product label and the material safety data
complete, and before placing reinforcing sheet (MSDS) to determine the flammability
steel. Applying form oil immediately after of the product youre using. If its flammable,
stripping increases the likelihood of then you must comply with the Construction
contaminating the workers handling and Regulations requirement that at least one
re-locating the form, and also makes the fire extinguisher (ULC 4A40BC rating) be
pieces more difficult to handle. Applying provided where flammable liquids or
form oil after the rebar is placed can lead to combustible materials are stored, handled,
contamination of the rebar. This does not or used. Every worker who may have to
pose an immediate hazard to the worker, but use the fire extinguisher is required to be
it can lead to the failure of the structure due trained. See the Construction Regulation
to an insufficient bond between the rebar for all of your responsibilities regarding
and the concrete encasing it. preventing fire.
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RUNNING
OILING FORMWORK
HEAD
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RUNNING HEAD
SLEEVES, BULKHEADS, BLOCK-OUTS, BUCKS
There are two basic types of sleeves. installed to preserve the shape of the frame
during the placing and curing phase get
1) Boxout sleeve. This is a form within the removed with the formwork, but the frame
form and is put in place to create an itself stays in place.
opening or pocket in the concrete. A boxout
can be made out of form-ply, metal, plastic, If the permanent presence of a sleeve would
concrete, or any other material strong create a problemsuch as when youre
enough to maintain its position and shape required to maintain fire separationsthen
while concrete is being placed. the sleeve will be removed. Otherwise,
some or all of it may stay in place.
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RUNNING
5) WATERSTOP
HEAD
5) WATERSTOP
HEALTH HAZARDS then pressed together and held until it cools
and solidifies, making a bond.
Depending on the application, waterstop
may or may not be metal. It may be
Exposure to fumes is hazardous in each type
necessary to connect two pieces of waterstop
of welding. Inhalation may be harmful to a
in an end-to-end manner on the jobsite. This
workers health. Splicing or welding should
process is referred to as welding, and in
only be done in well-ventilated areas. Protect
the case of metal waterstop (typically
exposed skin against burns from hot material,
stainless steel) its done by either TIG
and protect eyes from splash and spatter of
or MIG welding.
molten material as well as eye flash.
PHYSICAL HAZARDS
PVC/Rubber waterstop can be cut with a
utility knife, but given the durability of the
material, you may need to use a lot of force
to make the cut. This means that if you slip,
you can be severely injured.
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ERECTING
FORMWORK
39
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RUNNING HEAD
ERECTING FORMWORK
1) INTRODUCTION
Workers can use suitable pry bars to do create a trip or struck-against hazard for
the final positioning of heavy panels or workers in the area.
formwork. Beware of overexertion
injuries from trying to lift, push, or pull Placing rebar bundles on suspended slab
panels or formwork into place. Take care formwork is a critical safety issue. Spread the
when using a pry bar. Its leverage gives a bundles out around the deck. This disperses
worker the ability to move a very heavy the load. Reinforcing steel and all other
object a small distance with only moderate material must be placed on the deck in a
effort. But if the pry bar slips under the manner and location that does not overload
load, you can get injured. You can suffer the formwork, shoring, or any other part of
contusions, lacerations, or broken bones if the structure. Refer to the formwork
a pry bar slips and kicks back while under drawings for information about where to
heavy load. You can also be injured from a place material.
fall if the pry bar slips out under load.
Interior panels are carried or hoisted into
place, and are then fixed to the exterior
panels. They allow you to set the proper
form width. There are many products
commercially available to connect opposing
form panels, but the type, size, and quality
of tie specified in the design drawings must
be used without exception.
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ERECTING
RUNNING
FORMWORK
HEAD
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RUNNINGAND
RIGGING HEAD
CRANE WORK
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RIGGING AND
RUNNING
CRANE WORK
HEAD
An orange hard hat and vest make the signal person easy The connection between the crane and the load must be
to identify from the cab of the crane. secure.
guardrail or personal fall protection. When load could fall or the formwork could fail
signal persons are looking up at incoming during the pour.
loads, they may be unaware of how close
they are to the edge, and they risk falling. The load must be stable while it is
suspended, otherwise it can be hazardous to
land. The lift points must be located so that
INTERACTION WITH THE the load is suspended in the same position
FORMWORK CREW in which it will ultimately be used. The form
Riggers must be familiar with the loads that must hang stable and steady.
are being lifted, and know the type and size
of lifting hook required. They must attach If workers are exposed to a fall hazard, fall
hooks in a way that allows for quick and protection must be provided and used (see
easy disconnection once the load is in place, the Construction Regulation for how a fall
but which prevents hooks from rolling out hazard is defined). Lift points should be in
when the load is being lifted. Failing to
attach load hooks correctly, or using the
wrong load hooks, can lead to the load
falling.
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RUNNINGAND
RIGGING HEAD
CRANE WORK
locations that allow for easy access when greater risk of tripping or walking into
attaching and disconnecting lift lines. If the objects. Make braces visible, and install them
lift points cannot be reached from ground with consistent placement.
level, then suitable access must be provided.
Climbing the formwork or shoring towers is Kick plates are strips of material attached to
not an acceptable method of access. the deck or ground so that wall and column
forms are landed in the proper placeand
Tag linesropes hanging from corners of the stay in place. They act as a template, and are
loadare the safest and easiest way to placed before the installation of the forms. If
control the load as it is being lifted out and installed correctly, kick plates reduce the
lowered into place. It is important that there hazards associated with hoisting formwork
are no knots, hooks, etc., on the tag lines, by allowing the crew to focus on the task of
because these things can catch a workers landing the form on its pre-determined mark.
clothing or body and cause them to fall. They dont have to measure and make fine
adjustments to the panels position.
Tag lines should be long enough for workers
to reach them without risking being struck
by the load as it comes inbut not so long
as to coil up. A coil of rope is a tripping
hazard for workers trying to land a load.
Stepping in a coil when the load is being
lifted out can pull a worker off balance. It
can also lift the worker off the ground with
the load, leading to a fall.
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RUNNING HEAD
TIES
3) TIES
STRENGTH OF TIES allows the tie to be installed perpendicular
to the panel. If it is installed on an angle
Ties are specified as part of the design, and
from one panel to the other, the tie strength
should be shown on the formwork drawings.
is diminished. This means that the more
Different ties have different strengths, so
out-of-square the tie is relative to the form,
never make substitutions when installing
the weaker it becomes. This weakness
ties unless an engineer approves.
increases the chance of form failure.
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RUNNING HEAD
REINFORCING STEEL
4) REINFORCING STEEL
SMALL-SCALE PROJECTS machine. Whenever possible, rebar assemblies
On smaller projects, the carpenters who should be made on a workbench or table so
build the forms may be responsible for that workers are not forced to bend over.
installing the reinforcing steel as well.
On larger projects, there is typically a
CUTTING REBAR
crew dedicated full-time to placing rebar.
Regardless of who places the rebar, the Theoretically, rebar is fabricated specifically
carpenters will return to close in the form. for each project, so you shouldnt need to
cut bars on site. In many cases, however,
you often need to cut some bars to suit
PHYSICAL HAZARDS particular situations.
A common hazard when placing rebar is
overexertion, which can mean back injuries The tool often used for cutting is a gasoline-
and muscle strains. Practice proper lifting powered quick-cut saw. Workers must use
and back care techniques. For instructions, appropriate personal protective equipment,
refer to the Construction Health and Safety including eye and hearing protection. Make
Manual (M029), available from the sure that the saw has a metal cutting blade
Construction Safety Association of Ontario. before use. Always operate the saw in
a well-ventilated area to avoid the
accumulation of deadly carbon
monoxide fumes.
Tying rebar can lead to repetitive strain Prevent fire by operating the saw or
injuries, particularly in the wrist and forearm. torch well away from any flammable or
Changing hands while tying reduces the explosive substances. Even a workers
risk of injury. So does using a rebar tying clothing can be ignited by the shower of
sparks created by cutting rebar.
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REINFORCING
RUNNINGSTEEL
HEAD
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RUNNING AND
SHORING HEADBRACING
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CONCRETE
49
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RUNNING HEAD
PREPARATION BEFORE PLACING CONCRETE
*For full details on engineering and inspection requirements regarding forms, formwork, falsework, and re-shoring, see Sections 87-92 of
the Construction Regulation (O. Reg 213/91).
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LOCATION OF EQUIPMENT
The location of the pump or concrete
truck around formwork and the
excavation can have serious safety
consequences. The weight and vibration
of equipment can cause movement or
A scaffold or elevating work platform provides safe access
collapse of the soil or forms. All when pouring concrete.
** For full details on requirements for the top of excavations, see Section 233 of the Construction Regulation (O. Reg 213/91).
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ADDING WATER
Concrete slump is directly affected by
the amount of water, and is part of the
design of the concrete mix. The addition
of water at the site can delay the
concrete set time, which is a primary
factor in determining the pour rate.
Adding water may require a
corresponding reduction in the pour
rate. Unless an engineer has given
approval to do so, dont add water.
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PLACING
RUNNING
CONCRETE
HEAD
3) PLACING CONCRETE
BEFORE POURING important that the placing crew
understands the limitations of the
Before starting the pour, someone must
system and equipment they are
be designated to monitor the condition
using, and not go beyond them.
of the forms as the concrete
is placed. They must be able to identify
any sign of bulging, slipping, uplifting, CONVEYANCES
sagging, etc., and have the authority and
the means to stop the pour immediately. When using pumps, beware of
Extra shores and other material and overhead contact with electrical lines
equipment that might be needed in an the hazard of being struck by the
emergency must be readily available. equipment
Have a procedure to ensure worker line thrust causing damage to
safety in the event of any sign of form formwork or falsework from the
movement or failure. discharge pipe on the ground
pinch points.
POUR RATE
Understand and strictly adhere to the
rate, techniques, and procedures of the
pour. Forms are designed to accept
concrete at a certain rate, so
increasing the pour rate can cause
failure. This includes heaping or piling
concrete when pouring walls and
suspended slabs. Allowing concrete to
pile up in one location can overload the
form and lead to a collapse.
The worker discharging the bucket must have an
unobstructed work area.
The pour rate is specified on the
formwork drawings. Pouring techniques
Buckets present the hazards of
and procedures can vary site to site,
so they must be communicated to the striking workers
placing crew before starting the pour. overhead contact with electrical lines.
Improper placement of concrete can Keep workers not involved in the
cause uplift, upset, collapse or other pouring away from the buckets
kinds of formwork failure. It is landing area.
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RUNNING CONCRETE
PLACING HEAD
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CONSOLIDATION
RUNNING HEAD
4) CONSOLIDATION
PROPER USE OF VIBRATOR damage to the formwork, falsework, or
reinforcing steel from direct and prolonged
Vibration created by concrete consolidation
contact with the vibrator.
can cause the formwork to collapse if there
is insufficient diagonal bracing within the
Concrete vibrators must not be used as a
shoring assembly. Improper use of the
means of spreading concrete. Concrete
vibrator can also lead to form ties being
must be distributed evenly throughout
broken, causing formwork failure.
the formnot heaped and then vibrated
level. Heaping concrete overloads the
Shoring must be engineered. Follow design
formwork and can lead to collapse.
drawings to ensure that you dont overlook
diagonal bracing. Workers operating
The vibrator itself is a health issue. It can
vibrators must be trained to know the
affect the workers hands and arms. The
location of form ties. They should not
worker can get hand/arm vibration syndrome
strike ties with the vibrator.
(HAVS). See Physical Hazards in the
Hand/Skin Protection section of the
SIZE OF VIBRATOR Construction Safety Association of Ontarios
Construction Health and Safety Manual
The size of the vibrator head matters for
(M029), available on www.csao.org or by
successfully consolidating the concrete, and
calling 1-800-781-2726.
it also matters for safety. Its size must allow
it to fit within the spaces between the
reinforcing steel and the forms. If its too CONSOLIDATION TECHNIQUES
big, there will be areas that cant be reached
The worker operating the vibrator must
and consolidated, and there may also be
recognize where form ties, bulkheads,
sleeves, and block-outs are, and avoid hitting
them with the vibrator. Be cautious when
approaching corners with the vibrator. Corners
are the weakest part of the form, and have
a higher chance of failure if damaged.
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RUNNING HEAD
CONSOLIDATION
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RUNNING
FINISHING
HEAD
5) FINISHING
VENTILATION GUARDS
A gasoline-engine power trowel is the All guards must be in place on power
most common tool used to float and trowels. Its dangerous to operate any piece
finish concrete floors. Carbon of equipment with the guards removed.
monoxide (CO) from engine exhaust Also dangerous is bypassing built-in safety
is deadly, so you must have adequate devices.
ventilation.
Do NOT allow the use of or operate The critical safety feature on a power trowel
gasoline-powered engines or tools in is the circular frame around the outside of
poorly ventilated areas or near fresh- the trowel blades. This guard greatly reduces
air intakes. Using gasoline-powered the chance of the blades catching against
tools indoors where CO can an object while they are spinning.
accumulate can be fatal.
Overexposure to CO can occur in a
matter of minutes. See sections 46-47
of the Construction Regulation for
more information on ventilation and
the operation of internal combustion
engines.
Recognize the signs and symptoms
of CO overexposure:
headache
nausea
weakness
A power trowel with guards in place, being used in a
dizziness well-ventilated area.
vision problems
changes in behaviour If the blades do come in contact with
loss of consciousness. something, they can stop suddenly,
Any of these symptoms and signs can transferring the power to the frame of the
occur within minutes of exposure. machine and causing it to spin. Anything
Electrically powered engines or tools ranging from minor finger, hand, and wrist
may be used in enclosed or semi- injuries to fatal falls can result.
enclosed areas, but ventilation must
still be monitored. The drive-belt guard is another safety feature
on a power trowel. It protects against injury
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RUNNING HEAD
FINISHING
OTHER HAZARDS
Review and understand the material safety
data sheet (MSDS) for any hazardous product
used. Follow all of its instructions, including
those regarding
health hazards and required
protection
environmental issues.
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STRIPPING AND
REMOVAL
59
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RUNNING HEAD
STRIPPING AND REMOVAL
1) GENERAL
OVERVIEW green concrete has unpredictable
characteristics, and cannot be trusted to
The process of hardening that concrete
stand unsupported.
undergoes once it is poured is called curing.
Concrete becomes increasingly harder as
The strength of the concrete affects not only
time passes and it continues to cure.
stripping and re-shoring, but it also affects
According to the Construction Regulation,
the placement of guardrails. You must take
formwork and falsework shall not be
great care to ensure that the concrete is
removed unless
cured enough to support the attachment
the concrete is strong enough to
of guardrail postsespecially any posts
support itself and any loads that
that must be fastened into the concrete.
may be applied to the structure,
OR While formwork is being removed, workers
the concrete and the structure are must check the structure for loose concrete.
adequately re-shored. Any rubble, debris, spalling, or over-pour
must not be left on columns, walls, or other
The strength of the concrete is the most structures since it may fall unexpectedly and
critical factor relating to the stripping and injure workers below. Remove such material
removal of formwork and subsequent re- when the forms are being stripped.
shoring. It must be cured sufficiently to
maintain its shape once the formwork is You need personal protective equipment
removed. The type and placement of during the stripping stage, especially gloves
re-shoring is determined by the concrete and eye protection. Concrete can chip easily,
strength at time of stripping. and there are countless places where
pinches, cuts, scrapes, abrasions, and other
Commonly, sample cylinders of concrete injuries can occur. Wear eye protection,
are cast at various stages of each pour to gloves, and long sleeves at all times when
be used for testing. The concrete mix is stripping formwork.
designed to reach a certain strength after
a specific time. Compression tests are Formworkwhether knock-down forms,
performed on the cylinders to verify that fly forms, or gang formsmust be braced
this strength has been reached. Once this sufficiently to prevent it from falling, while
has been confirmed through testing, the allowing it to be broken free of the concrete.
stripping process can begin. Falling formwork can hit workers and
damage equipment.
Stripping forms before verifying cylinder
strength is a dangerous, extremely risky
practice, so dont do it. Undercured,
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STRIPPINGRUNNING
AND REMOVAL
HEAD
Workers must not be allowed to throw having the broken tool strike them
material to the ground from a work or another worker
platform. Stripped material must be losing balance and falling.
placed securely on the platform and
then lowered by a controlled means Regardless of the task, choose the
to the ground. appropriate tool and use it correctly in
accordance with the manufacturers
instruction manual.
MATERIAL HANDLING
There is a high risk of overexertion during If a specialized tool is needed to remove
stripping and removal of formwork. form ties, make sure that you use that
Reaching, prying, pulling, and pushing, specific tool. Substituting a hammer or pliers
as well as lifting and carrying, can put in place of a tool designed and manufactured
considerable strain on joints, muscles, to remove a certain type of form tie
and bones. increases the risk of injury.
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STRIPPING AND REMOVAL
ACCESS
A proper work platform with safe access
must be provided for workers stripping
forms at any height above the ground. If
workers are stripping forms in an area with a
fall hazard, fall protection must be provided
and used.
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KNOCK-DOWN RUNNING
SLAB SYSTEMS
HEAD
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FLYFORMS
3) FLYFORMS
Flyform for suspended slabs is typically built Re-shoring begins immediately behind the
on jacks so that once the concrete is removal of the flyform. This provides
sufficiently set, the form can be lowered to support so that the form can be placed on
remove it from service. Working from top of the slab from which it was removed.
underneath, the jacks are released and the Hazards at this stage are:
weight of the flyform is transferred to rollers, Falls off the open edge because
which makes it easier to move. It is then guardrails must be taken down to
pushed out to the open edge of the allow for removal of the form.
structure. As it emerges from under the Workers must use personal fall
recently completed suspended slab, it is protection systems during the
connected to the crane. stripping and removal phase of fly
forming.
Being crushed, or being struck by
the form, when rolling the form out.
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SUMMARY
SUMMARY
Regardless of the type of formwork, At least one competent worker must
following these steps will help minimize monitor the forms for movement
risks and hazards: during concrete placing, and such
a worker must have the authority
Formwork (formwork, falsework, to immediately stop the pour if any
re-shoring) must be designed by problems develop.
a professional engineer, or the
formwork components must be tested Sample concrete cylinders must be
to failure and the test results verified cast at random times during each
by a professional engineer. pour, and be allowed to cure in the
same conditions that the building or
The formwork must be built in structure will face.
accordance with the engineered
drawings. Subject the concrete cylinders to
compression testing at pre-determined
An inspectionby a professional intervals to verify the strength of the
engineer or the engineers designated concrete.
inspectormust be done to verify
that the formwork has been installed Stripping of falsework and formwork,
according to the engineered drawings. and re-shoring must be done only
when testing verifies that the concrete
The person who carries out the has reached the required strength.
inspection must put the findings Stripping and re-shoring must be
of the inspection in writing. done only in the manner described
and detailed in the engineers
If there is a deviation from the drawings.
engineered drawing, the professional
engineer must review the deviation
and make any necessary amendments
either to the drawing or to the actual
jobsite implementation of the
formwork. The drawing and the
reality of the formwork must be
consistent.
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Notes
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Notes
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