DRAFT Formwork Falsework COP

8/10/2019 DRAFT Formwork Falsework COP

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This DRAFT Code has been approved by Safe Work Australia Members and is ready for approval by theSelect Council on Workplace Relations (Ministerial Council ). This Code will become a model WHS Code ofPractice under the Inter- Governmental Agreement for Regulatory and Operational reform in OHS when it isapproved by the Ministerial Council.

FORMWORK AND FALSEWORK

Code of Practice


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TABLE OF CONTENTS

FOREWORD ..................................................................................................................... 3

SCOPE AND APPLICATION ............................................................................................ 3

1

INTRODUCTION ......................................................................................................... 4

1.1 What is formwork and falsework? ................................................................................. 41.2 Who has health and safety duties in relation to formwork and falsework activities? ...... 51.3 What is involved in managing risks associated with formwork and falsework activities? 61.4 Information, training, instruction and supervision .......................................................... 7

2 THE RISK MANAGEMENT PROCESS ...................................................................... 92.1 Identifying the hazards .................................................................................................. 92.2 Assessing the risks ....................................................................................................... 92.3 Controlling the risks ...................................................................................................... 92.4 Maintaining and reviewing control measures .............................................................. 11

3

PLANNING................................................................................................................ 12

3.1 Construction project and principal contractor .............................................................. 123.2 Safe work method statements .................................................................................... 133.3 Designers ................................................................................................................... 133.4 Formwork and falsework design ................................................................................. 163.5 Adjacent buildings or structures .................................................................................. 193.6 Falls ............................................................................................................................ 193.7 Working near electric lines .......................................................................................... 193.8 Securing the work area ............................................................................................... 203.9 Emergency plan .......................................................................................................... 21

4 WORK METHODS AND SYSTEMS ......................................................................... 224.1 Traditional and modular formwork systems ................................................................. 224.2

Slip forms and jump forms .......................................................................................... 23

4.3 Travelling formwork .................................................................................................... 24

5 FORMWORK AND FALSEWORK ACTIVITIES ....................................................... 265.1 Foundations and footings............................................................................................ 265.2 Erecting formwork and falsework ................................................................................ 265.3 Constructing formwork ................................................................................................ 275.4 Crane and load handling ............................................................................................. 345.5 Inspecting and monitoring ........................................................................................... 365.6 Stripping formwork ...................................................................................................... 365.7 Dismantling falsework ................................................................................................. 38

6

SPECIFIC HAZARDS AND CONTROL MEASURES ............................................... 396.1 Wall and column forms ............................................................................................... 39

6.2 Slip, jump and travelling forms .................................................................................... 40

APPENDIX A DEFINITIONS ........................................................................................ 45


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FOREWORD

This Code of Practice for managing risks associated with formwork and falsework activities is anapproved code of practice under section 274 of the Work Health and Safety Act (the WHS Act).

An approved code of practice is a practical guide to achieving the standards of health, safetyand welfare required under the WHS Actand the Work Health and Safety Regulations (theWHS Regulations).

A code of practice applies to anyone who has a duty of care in the circumstances described inthe code. In most cases, following an approved code of practice would achieve compliance withthe health and safety duties in the WHS Act, in relation to the subject matter of the code. Likeregulations, codes of practice deal with particular issues and do not cover all hazards or riskswhich may arise. The health and safety duties require duty holders to consider all risksassociated with work, not only those for which regulations and codes of practice exist.

Codes of practice are admissible in court proceedings under the WHS Act and Regulations.Courts may regard a code of practice as evidence of what is known about a hazard, risk or

control and may rely on the code in determining what is reasonably practicable in thecircumstances to which the code relates.

Compliance with the WHS Act and Regulations may be achieved by following another method,such as a technical or an industry standard, if it provides an equivalent or higher standard ofwork health and safety than the code.

An inspector may refer to an approved code of practice when issuing an improvement orprohibition notice.

This Code of Practice has been developed by Safe Work Australia as a model code of practiceunder the Council of Australian Governments Inter-Governmental Agreement for Regulatoryand Operational Reform in Occupational Health and Safetyfor adoption by the Commonwealth,

state and territory governments.A draft of this Code of Practice was released for public consultation on 2 April 2012 and wasendorsed by the Select Council on Workplace Relations on [to be completed].

SCOPE AND APPLICATION

This Code provides practical guidance to persons conducting a business or undertaking on howto comply with their health and safety duties when carrying out construction work involvingformwork and falsework activities, including high risk construction work.

This Code should be read in conjunction with the Code of Practice: Construction Workwhich

provides further guidance for persons conducting a business or undertaking involvingconstruction work and high risk construction work.

How to use this Code of PracticeIn providing guidance, the word should is used in this Code to indicate a recommended courseof action, while may is used to indicate an optional course of action.

This Code also includes various references to sections of the WHS Act and Regulations whichset out the legal requirements. These references are not exhaustive. The words must,requires or mandatory indicate a legal requirement exists and must be complied with.


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1 INTRODUCTION

1.1 What is formwork and falsework?

Formwork and falsework are temporary structures that support parts or the whole of a

permanent structure until it is self-supporting. Individual components of formwork and falsework,for example scaffolding, are plant. Once assembled the components form the temporarystructure. Some formwork and falsework systems are designed to remain with the permanentstructure.

Generally, work carried out to design, construct, erect, alter, maintain, dismantle or removeformwork or falsework will be defined as construction work.

Formworkmeans the surface, support and framing used to define the shape of concrete until itis self-supporting.

Formwork includes the forms on or within which the concrete is poured, the supportswhich carry the forms and the concrete, the bracing which may be added to ensurestability, as well as the foundations and footings.

When complete, the formwork is sometimes referred to as the formwork assembly. Although commonly referred to as part of the formwork, the formwork supports, bracing,

foundations and footings are referred to as falsework.

Falseworkmeans the temporary structure used to support a permanent structure, material,plant, equipment and people until the construction of the permanent structure has advanced tothe stage that it is self-supporting.

A temporary structural support system referred to as falsework includes the foundations,footings and all structural members supporting the permanent structural elements.

Falsework is commonly used to support spanning or arched structures, for example

bridges, while they are being constructed. The temporary support structures for formwork (see above) used to mould concrete to

form a desired shape and the scaffold that might also give workers entry to the structurebeing constructed is sometimes referred to as falsework.

What is construction work?

R.289: Construction work means any work carried out in connection with the construction,alteration, conversion, fitting-out, commissioning, renovation, repair, maintenance,refurbishment, demolition, decommissioning or dismantling of a structure.

Construction work includes: installation or testing carried out in connection with an activity referred to in the definition

above the removal from the workplace of any product or waste resulting from demolition the prefabrication or testing of elements, at a place specifically established for the

construction work, for use in construction work the assembly of prefabricated elements to form a structure, or the disassembly of

prefabricated elements forming part of a structure the installation, testing or maintenance of an essential service in relation to a structure work connected with an excavation work connected with any preparatory work or site preparation (including landscaping as

part of site preparation) carried out in connection with an activity referred to the definition

above


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an activity referred to in the definition above that is carried out on, under or near water,including work on buoys and obstructions to navigation.

Formwork and falsework may include construction work that is defined as high risk constructionworkin the WHS Regulations for which a safe work method statement must be prepared beforethe work starts.

Further guidance on what is construction work and safe work method statements is available inthe Code of Practice: Construction Work.

Other key terms used in this Code are defined in Appendix A.

1.2 Who has health and safety duties in relation to formwork and falseworkactivities?

A person conducting a business or undertaking has the primary duty to ensure, so far as isreasonably practicable, workers and other people are not exposed to health and safety risksarising from the business or undertaking.

This duty requires the person to manage risks by eliminating health and safety risks so far as isreasonably practicable, and if it is not reasonably practicable to eliminate the risks, byminimising those risks so far as is reasonably practicable.

There are more specific requirements to manage risks under the WHS Regulations, includingthose associated with plant, construction work, falls, noise and hazardous manual tasks.

For clarity, the person conducting a business or undertaking who carries out formwork andfalsework activities is referred to in this Code as the formwork or falsework installer.

A principal contractorfor a construction project- where the cost of the construction work is$250,000 or more - has additional duties under the WHS Regulations, including to:

take all reasonable steps to obtain from each person conducting a business orundertaking that is to carry out high risk construction work a copy of the safe workmethod statement relating to that work before the high risk construction work starts

prepare a written work health and safety management plan for the workplace beforework on the construction project starts.

Designersof structures, including temporary structures, must ensure so far as is reasonablypracticable the structure is without risks to health and safety when used for a purpose for whichit was designed. Designers must give the person who commissioned the design of thetemporary structure a written safety report, see section 3.2 of this Code. Pre-fabricatedformwork must have its design registered under Part 5 of the WHS Regulations for plant.

Manufacturers, importers and suppliersmust ensure, so far as is reasonably practicable,plant and structures they manufacture, import or supply are without risks to the health andsafety of people. Each of these duty holders must provide information about the plant to thenext duty holder along the entire supply chain and ultimately to the buyer.

Installersmust ensure, so far as is reasonably practicable, the way the plant or structure isinstalled is without risks to the health and safety of people who install, use, decommission ordismantle the plant or structure and others who are at or near of the workplace.

Officers, such as company directors, have a duty to exercise due diligence to ensure thebusiness or undertaking complies with the WHS Act and Regulations. This includes takingreasonable steps to ensure the business or undertaking has and uses appropriate resources

and processes to eliminate or minimise risks from the construction work.


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Workers have a duty to take reasonable care for their own health and safety and to notadversely affect other peoples health and safety. Workers must co-operate with reasonablepolicies or procedures relating to health and safety at the workplace and comply, so far as theyare reasonably able, with reasonable instructions. If personal protective equipment is providedby the business or undertaking, the worker must so far as they are reasonably able, use or wearit in accordance with the information, instruction and training provided.

Other persons at the workplace, like visitors, must take reasonable care for their own healthand safety and must take reasonable care not to adversely affect other peoples health andsafety. They must comply, so far as they are reasonably able, with reasonable instructionsgiven by the person conducting the business or undertaking to allow that person to comply withthe WHS Act.

1.3 What is involved in managing risks associated with formwork and falseworkactivities?

R.297:A person conducting a business or undertaking must manage risks associated withcarrying out construction work.

R.32-38: To manage risk, a person conducting a business or undertaking must:

identify reasonably foreseeable hazards that could give rise to risks to health and safety

eliminate risks to health and safety so far as is reasonably practicable

if it is not reasonably practicable to eliminate risks to health and safetyminimise thoserisks so far as is reasonably practicable by implementing risk control measures according tothe hierarchy of control in regulation 36

ensure the control measure is, and is maintained so that it remains, effective, and

review and as necessary revise control measures implemented to maintain, so far as isreasonably practicable, a work environment that is without risks to health or safety.

Chapter 2 of this Code provides guidance on how to manage the risks associated with cash-in-transit activities following a systematic process which involves:

identify hazards find out what could cause harm assess risks if necessary understand the nature of the harm that could be caused by the

hazard, how serious the harm could be and the likelihood of it happening control risks implement the most effective control measures that are reasonably

practicable in the circumstances review control measuresto ensure they are working as planned.

Further guidance on the risk management process generally is available in the Code ofPractice: How to Manage Work Health and Safety Risks.

Consulting your workers

S.47:The person conducting a business or undertaking must, so far as is reasonablypracticable, consult with workers who carry out work for the business or undertaking who are, orare likely to be, directly affected by a matter relating to work health or safety.

S.48: If the workers are represented by a health and safety representative, the consultationmust involve that representative.

Consultation involves sharing information, giving workers a reasonable opportunity to express

views and taking those views into account before making decisions on health and safetymatters.


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experienced and trained in formwork and falsework and authorised to ensure the work is carriedout in accordance with the applicable safe work method statement.

Further information on general construction induction training and other training is available inthe Code of Practice: Construction Work.


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2 THE RISK MANAGEMENT PROCESS

2.1 Identifying the hazards

The first step to manage risks is to identify the hazards associated with formwork and falsework

activities. Examples of formwork and falsework hazards include: formwork or falsework collapse before, during and after placement of concrete or the

structural members to be supported working at height falling objects slips and trips noise dust manual tasks.

2.2 Assessing the risks

A risk assessment involves considering what could happen if someone is exposed to a hazardand the likelihood of it happening.

Many hazards and their associated risks are well known and have well established andaccepted control measures. In these situations, the second step to formally assess the risk isunnecessary. If, after identifying a hazard, you already know the risk and how to control iteffectively, you may simply implement the controls.

When assessing risks involved with formwork and falsework you should consider things like: the type of form or falsework elements to be used the height of the formwork or falsework to be erected

the size of the formwork deck or other platforms included in the falsework the location of intermediate working platforms the scheduling of the work the layout of the workplace, including whether there are fall hazards both for people and

objects the number of people involved what plant and equipment will be used and the skill and experience required to use it

safely what exposures might occur, e.g. noise or ultra-violet radiation local weather conditions, particularly wind forces.

It should then be possible to select the most suitable work methods and arrangements toeliminate or minimise risks, for example:

items of plant and equipmentlarge structures may require scaffolding or mobile plant towork on suspended floors

minimise the working heights for people erecting and dismantling the formwork orfalsework

safe temporary work platforms where work at height is required plant and material placement and storage to minimise manual handling.

2.3 Controlling the risks

Some control measures are more effective than others. Control measures can be ranked fromthe highest level of protection and reliability to the lowest. This ranking is known as thehierarchy of control.


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Eliminating the risk

This means removing the hazard or hazardous work practice from the workplace. This isthe most effective control measure and must always be considered before anything else.

If eliminating the risk is not reasonably practicable, you must consider using substitution,isolation or engineering controls, or a combination of these control measures, to minimise therisk.

Minimising the risk

Substitution

Minimise the risk by substituting or replacing a hazard or hazardous work practice with a saferone. Examples include:

using a type of formwork that can be preassembled on the ground and then lifted intoposition by a crane which reduces the need to work at height and therefore the risk ofpeople or objects falling

using a crane to lift formwork or falsework components instead of manual lifting

minimises the risk of musculoskeletal disorders.Isolation

Minimise the risk by isolating or separating the hazard or hazardous work practice from people.For example, isolating people working on falsework and formwork from mobile plant withphysical barriers will minimise the risk of contact occurring between a person and the mobileplant.

Engineering Controls

Engineering controls are physical control measures to minimise risk, for example install fallprevention devices like guard rails, toe boards and edge protection to minimise the risk of aperson or object falling from height.

If a risk then remains, the duty holder must minimise the remaining risk, so far as is reasonablypracticable, by using:

Administrative controls

Administrative controls should only be considered when other higher order control measuresare not reasonably practicable, or to increase protection from the hazard. These are workmethods or procedures that are designed to minimise the exposure to a hazard, for exampleinstall warning signs near the formwork and falsework activity.

Any remaining risk must be minimised, as far as is reasonably practicable, by providing and

Personal protective equipment

Personal protective equipment (PPE) is the lowest order control measure in the hierarchy ofcontrols. PPE should also only be considered when other higher order control measures are notreasonably practicable or to increase protection from the hazard. Examples of PPE includehats, hearing protectors and high visibility vests.

Administrative control measures and PPE rely on human behaviour and supervision, and usedon their own, tend to be least effective in minimising risks.

Combining control measuresIn most cases, a combination of the controls measures will provide the best solution to minimisethe risk to the lowest level reasonably practicable. You should check your chosen controlmeasures do not introduce new hazards. For example, protect workers from falls using fallprotection devices like guard rails (engineering) and other workers from falling objects by

establishing an exclusion zone for the work area (isolation) and providing hard hats (personal


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protective equipment). You should check your chosen control measures do not introduce newhazards.

2.4 Maintaining and reviewing control measures

R.37:A person conducting a business or undertaking must ensure control measures are

maintained so that they remain effective, including by ensuring that the control measures areand remain: fit for purpose suitable for the nature and duration of the work, and installed, set up and used correctly.

R.38:A duty holder must review and as necessary revise control measures implemented tomaintain, so far as is reasonably practicable, a work environment that is without risks to healthor safety.

The control measures put in place to protect health and safety should be regularly reviewed to

make sure they are effective, including then there is a change at the workplace. For example,control measures should be reviewed:

when an injury or illness occurs because of a hazard the risk assessment addressed, orfailed to consider

before making changes to work procedures if new information becomes available to indicate a control measure may no longer be the

most effective when there are changes to who is engaged to carry out work.

Control measures can be reviewed and revised in consultation with workers and their healthand safety representatives. Workers are often able to quickly identify and propose solutions to

problems when they occur.

Controls should be checked by using the same methods as the initial hazard identification andrisk assessment. If a hazard is not eliminated or minimised by the chosen control measures, goback through the risk management steps, review the information and make further decisionsabout risk control.

When reviewing control measures, a safe work method statement must also be reviewed andrevised where necessary.


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3 PLANNING

Formwork and falsework activities should be planned before work starts so it can be carried outsafely. Planning involves identifying the hazards, assessing the risks and determiningappropriate control measures in consultation with the people involved in the work, including theprincipal contractor, the formwork or falsework installer, designers and mobile plant operators.

Consultation should include discussions on the: nature or condition of the ground or working environment weather conditions nature of the work and other activities that may affect health and safety

interaction with other trades

site entry

safe work method statement management of mobile plant and surrounding vehicular traffic

type of equipment used for formwork and falsework

public safety

provision of adequate amenities

procedures to deal with emergencies

skills and training of workers.

3.1 Construction project and principal contractor

Where the value of construction work is $250,000 or more, it becomes a construction project

requiring a principal contractor. There can only be one principal contractor for a constructionproject and this will be either the person commissioning the construction work or a personappointed as the principal contractor by the person commissioning the construction work.

The principal contractor has a range of duties for a construction project including: preparing and reviewing a work health and safety management plan getting a safe work method statement before high risk construction work starts putting in place arrangements to manage the work environment, e.g. facilities, first aid,

traffic management and emergency planning installing signs showing the principal contactors name, contact details and location of

site office securing the construction workplace.

Although unlikely, it is possible the formwork or falsework installer will be the principalcontractor. This might occur, for example, where there is significant formwork and falseworkactivity required and it forms the bulk of the construction work. In this case, the formwork orfalsework installer, as the principal contractor, must comply with the principal contractor duties.

Further guidance on principal contractor duties can be found in the Code of Practice:Construction Work.


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3.2 Safe work method statements

R.299:A person conducting a business or undertaking that includes the carrying out of high riskconstruction work must, before high risk construction work commences, ensure that a safe workmethod statement for the proposed work: is prepared, or has already been prepared by another person.

A safe work method statement must be prepared for high risk construction work before the workstarts.

A range of activities defined as high risk construction work may be carried out as part offormwork and falsework, including work:

involving a risk of a person falling more than 2 metres involving structural alterations or repairs that require temporary support to prevent

collapse carried out on or near energised electrical installations or services carried out at a workplace in which there is movement of powered mobile plant carried out in or near a shaft or trench with an excavated depth greater than 1.5 metres.

The safe work method statement must: identify the type of high risk construction work being done specify the health and safety hazards and risks arising from that work describe how the risks will be controlled describe how the control measures will be implemented, monitored and reviewed

Safe work method statements must be developed in consultation with workers and theirrepresentatives who are carrying out the high risk work.

Further guidance on safe work method statements including a template and example of a safework method statement is available in the Code of Practice: Construction Work.

3.3 Designers

S.22:A person (the designer) who conducts a business or undertaking that designs plant or astructure that is to be used, or could reasonably be expected to be used, as, or at, a workplacemust ensure, so far as is reasonably practicable, that the plant or structure is designed to bewithout risks to the health and safety of persons who:

use the plant or structure at a workplace for a purpose for which it was designed store the plant construct the structure

carry out any reasonably foreseeable activity at a workplace in relation to themanufacture, assembly or use of the plant or structure for a purpose for which it wasdesigned, or the proper storage, decommissioning, dismantling or disposal of the plantor structure, or

are at or in the vicinity of a workplace and who are exposed to the plant or structure atthe workplace or whose health or safety may be affected by one of the above uses oractivities.

A designer of formwork or falsework is responsible for the planning and design of the completestructure. This includes the design of the formwork support structure, that is falsework, theformwork deck and connection details. There are two design activities relating to formwork andfalsework being the design of:

the items of plantthe formwork or falsework system


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the structure formed from the items of plantinstalling the system.

This means there may be more than one designer having duties in the formwork and falseworkprocess.

For manufacturing, assembling, constructing, using and proper dismantling and disposing ofplant or a structure, designers have a duty under the WHS Act to:

carry out, or arrange the carrying out of calculations, analysis, testing or examinationnecessary for the structure to be without risks to the safety of people

provide adequate information to each person who is provided with the design to giveeffect to it concerning conditions necessary to ensure the structure is without risks tohealth and safety.

Designers safety report for construction work

R.295:The designer of a structure or any part of a structure that is to be constructed must givethe person conducting a business or undertaking who commissioned the design a written reportthat specifies the hazards relating to the design of the structure that, so far as the designer is

reasonably aware: create a risk to the health or safety of persons who are to carry out any construction work on

the structure or part, and are associated only with the particular design and not with other designs of the same type of

structure.

Formwork and falsework is construction work. A safety report must be prepared for a specific orunusual design but not for common designs for which the risks are already known. For example,a design that specifies an unusual structure for a specific application may introduce uniquehazards that require specific risk controls.

A person commissioning the construction work must consult, so far as is reasonably practicable,

with the designer of the whole or any part of the structure about eliminating and controlling risks.The general duty to provide information under the WHS Act may be met through the designerssafety report prepared under the WHS Regulations.

A written safety report may include proprietary documentation setting out how to use acomponent or component system safely, formwork or falsework methods and health and safetyrisk control measures to be used.

If the person commissioning the construction work did not commission the design they musttake all reasonable steps to obtain any relevant designers safety report.

Where there is a principal contractor, the person conducting a business or undertaking whocommissioned the formwork and falsework design must give a copy of any relevant designers

safety report to the principal contractor.Further guidance on the safe design of buildings and structures can be found in theCode ofPractice: Safe Design of Structures.

Technical standardsA designer may use a technical standard or combination of standards and engineeringprinciples relevant to the design requirements as long as the outcome is a design that meetsregulatory requirements, including for work health and safety laws. Engineering principles wouldinclude, for example, mathematical or scientific procedures outlined in an engineering referencemanual or standard.

Design requirements will vary depending on whether the design is for prefabricated formwork

components or for more complex formwork or falsework structures.


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Plant design

Designer duties apply to a person conducting a business or undertaking who modifies thedesign during manufacture, or modifies existing plant, so that new measures for controlling riskare required.

An importer of prefabricated formwork or falsework who is unable to source the necessaryinformation from the original designer assumes the designer responsibility to demonstrate theplant satisfies the relevant health and safety requirements. This can be achieved by having acompetent person develop the information for the supplier.

Plant design registrationAll items of plant requiring design registration under Part 1 of Schedule 5 to the WHSRegulations, including prefabricated formwork, must be registered before use. The person withmanagement or control of the prefabricated formwork must ensure the design registrationnumber is kept so it is readily accessible near the prefabricated formwork.

If a person conducting a business or undertaking is hiring prefabricated formwork, the supplier

must provide the design registration number, usually on the supply docket or agreement. Thisdesign registration information must be kept at the workplace where the prefabricated formworkis to be used.

Further information on safe design principles and plant design registration can be found in theCode of Practice: Safe Design, Manufacture, Import and Supply of Plant.

Structure designAnything constructed to support a load can be referred to as a structure, including formwork andfalsework.

The term designer includes anyone who modifies the design. For example, if the capacity of

formwork is to be increased by adding more components, a designer will need to completeadditional calculations to ensure the modified structure is capable of supporting the additionalload. The person designing the addition has designer duties and, if they are not the originaldesigner, they should consult the original designer to ensure the new configuration does notcompromise the existing design specifications or safety factors.

The design of an in-situ constructed concrete structure can have a major effect on the ease offormwork construction and on the health and safety of people during construction. Generally,the more basic and simple the final concrete structure, the safer it is to construct, erect anddismantle the formwork.

An experienced formwork designer should be consulted during the design of a temporary

structure for in-situ concrete construction to provide input on ways to minimise health and safetyrisks arising from formwork activities. Some of the design measures considered to minimiseexposure to risk of injury during the construction of formwork include:

Reducing variations in the floor depth, that is, construct a floor so it has one consistentdepth. Formwork decks that are a consistent depth are easier to erect than variabledepth floors and minimise the risk of injury. Deeper beams introduce drop downs intothe floor, creating trip and fall hazards and require more work to construct and strip afterpouring.

Where beam forms are essential, provide suitable access across the beam recess toprevent injury to workers from stepping into the form during construction.

Reducing the number of columns required and, where columns do exist, eliminate

capitals and dropdowns.


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Utilise precast columns and beams. This can minimise the risks associated with fixingreinforcement, erecting and stripping column formwork and pouring concrete on site.Work activities carried out in a factory environment are generally lower risk.

Reducing cantilevered floor sections. Planning for manual tasks. Consideration should be given to the suitability of the design

of different formwork systems that will minimise manual handling risks, including:o table formso systems with lighter weights of materials to be handledo methods of formwork erection, alteration and dismantlingo improved entry and exit for workers and movement of materials and equipment

Considering sufficient clearance to adjacent structureso methods for moving large and heavy components, materials and equipment, i.e.

making allowances for a crane and other mechanical lifting devices to be used.

Where falsework is required to support a complex structure during construction, for example astone arch bridge, the falsework designer should be involved in the structural design tominimise the falsework complexity and minimise risk during its construction and dismantling.

The design process may be simple or complex depending on the size and complexity of thestructure involved. However, it is important the person who designs formwork and falsework iscompetent to do so. This includes but is not limited to a civil engineer experienced in structuraldesign, to ensure it is capable of carrying the loads that will be applied to it.

3.4 Formwork and falsework design

Formwork and falsework designers should consider the work practices necessary to carry outthe erection and dismantling of the formwork or falsework as designed and identify health andsafety risks and controls at the design stage. Design matters to consider include:

using designs that do not require in-situ formwork, e.g. tilt-up or precast concrete

elements can be constructed elsewhere and lifted into position the method and sequence of erecting and dismantling the formwork and falsework and

its supports and the related risks, e.g. manual handling providing safe entry to and exit from the work areas on and around the formwork and

falsework minimising the working heights for people erecting and dismantling formwork and

falsework allowing for guard rail systems, including toeboards, perimeter safety screens,

scaffolding or other means to be installed when working at heights allowing for fall arrest systems including safety lines to be installed if required providing advice and information, e.g. drawings, scope of work instructions and bills of

quantity, to the formwork or falsework installer and the principal contractor about whereextra safety precautions may be required, e.g. using multiple level frames or highstrutting

identifying hazards and appropriate risk control measures in the design, e.g. slopingsurfaces on formwork are slip hazards

limiting significant changes in the floor depth where possible design a floor with oneconsistent depth. Decks with a consistent depth are easier to erect and minimise therisk of injury because deeper beams can mean significant dropdowns into the deck

reducing the number of columns requiredwhere columns exist, design the columns socapitals or dropdowns do not exist

reducing cantilevered floor sections determining the vertical pour rates for walls, columns and other vertical concrete

elements before completing the formwork and falsework installation design.


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Formwork designFormwork should be rigid, watertight, braced and tied together to maintain position and shapeduring construction activities. It should be constructed in such a way so it can be removed easilyand safely, without damaging the formed concrete. Where formwork is to be re-used, theformwork design should ensure form strength is retained after allowing for the deterioration ofmaterials through use and handling.

Formwork drawings should include details of formwork, formwork joints, sealing procedures,ties, size and spacing of framing and details of proprietary fittings or systems proposed to beused. Details of the construction and erection sequence should be included on the drawings ifrequired. Where special requirements like external vibration are involved, the formwork designshould include additional structural loads to be applied.

Falsework designFalsework can be used to support a range of permanent structures before their completion,including formwork for wet concrete as well as major precast concrete elements or steelsections, for example bridges (see Figure 1).

Off-the-shelf support systems are generally not suited to support complex arrangements unlessused as part of a specifically designed solution and documented by the design engineer.

Figure 1Falsework supporting precast concrete bridge span

Falsework should be designed to carry all loads that may be applied, including the: Dead load - includes the mass of falsework, structural elements to be supported,

formwork, wet concrete, concrete reinforcement and any other embedded material. Superimposed load - includes the mass of workers, plant, equipment and runways,

stacked material and an impact allowance in addition to the imposed weight of anymechanically operated plant acting on the formwork or falsework.

Wind load the loads acting on the exposed area of falsework, formwork and any object

supported by the falsework or formwork.


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Horizontal loading - includes wind loading, horizontal surge loading for any mechanicallyoperated plant and any loading occurring during construction.

Other loads - includes any special conditions likely to occur during construction,including the redistribution of the load due to the effects of prestressing or earlyapplication of prestress, construction stages and staged removal of falsework. The

falsework design should also allow for, where required, the effects of water flow, trafficimpact, flooding and any other applicable conditions.

Figure 2Falsework under construction for road bridge

Falsework should not be designed to be supported or braced from completed permanentstructural elements unless it can be demonstrated such temporary loading will not affect thestructural integrity of the relevant permanent element or the stability and integrity of the overallfalsework system.

Adequate bracing should be provided longitudinally and transversely to ensure the falsework isstable during erection and significant horizontal movements resulting from the applied loads arelimited.

A site-specific geotechnical investigation should be carried out by a competent person inaddition to any geotechnical investigation required for the design of the permanent structure.This will enable the designer to establish whether the existing ground conditions are suitable forthe design and construction of the falsework system.

The foundations and footings of the falsework should be designed to prevent excessivesettlement and rotation of supports and to maintain overall structural integrity of the falseworkand the permanent structure or formwork being constructed.

Where the foundation material can become saturated with water, the possibility of reducedbearing capacity that could result in reduced stability and increased settlement or lift of thefoundation needs to be considered.

Note Using timber footing pads is not recommended and timber should not be used if there is a

possibility of the pads being under water for even a short period. If timber footings are used,they should be checked for the ability of the timber to withstand the applied crushing and other


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stresses. A competent person, for example the design engineer, should check and certify thatthe timber used is of the type and grade specified in the design.

The design drawings should include design assumptions and a statement of the loads anddimensional changes expected due to loading in all members of the falsework. The drawingsshould detail member sizes and materials, dimensions, levels, erection procedures and otherrelevant details including bracing, connections and foundations to ensure erection andinspection of the falsework can be done safely. The design should also include details ofmethods to provide safe entry to working zones of temporary and permanent structures.

If changes are made to a construction procedure, the appropriate drawing or other documentshould be updated and show revisions clearly. Provisional updating by marking up or preparinga hand drawn detail and signing and dating the mark-up or new detail should be countersignedby the designer and, where applicable, the design verifier.

3.5 Adjacent buildings or structures

Where the formwork or falsework activity is likely to reduce the security or stability of any part of

any adjacent structure, the work must not start or continue unless adequate steps are taken tocontrol the risk to any person from the:

collapse of the formwork or falsework or the permanent structure it supports onto theadjacent building or structure

collapse of the adjacent building or structure, or a part of the building or structure.

3.6 Falls

R.78:A person conducting a business or undertaking must manage risks to health and safetyassociated with a fall by a person from one level to another that is reasonably likely to causeinjury to the person or any other person. This includes the risk of a fall: in or on an elevated workplace from which a person could fall in the vicinity of an opening through which a person could fall in the vicinity of an edge over which a person could fall on a surface through which a person could fall, or in any other place from which a person could fall.

Any construction work, including formwork and falsework, involving a risk of a person fallingmore than 2 metres is defined by the WHS Regulations as high risk construction work and asafe work method statement must be prepared before this work starts.

Further guidance on managing the risks associated with falls and using ladders is available inthe Code of Practice: Managing the Risk of Falls at Workplaces.

3.7 Working near electric lines

R.166:A person conducting a business or undertaking at a workplace must ensure, so far as isreasonably practicable, that no person, plant or thing at the workplace comes within an unsafedistance of an overhead or underground electric line.

If this is not reasonably practicable to ensure the safe distance, the person must ensure that arisk assessment is conducted for the proposed work and control measures implemented areconsistent with the risk assessment and the requirements of an electricity supply authoritywhere it is responsible for the electric line..

Electric lines pose significant risks, including electrocution, arcing, explosion or fire causingburns, unpredictable cable whiplash and other objects being electrified such as signs, poles,


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trees or branches. Construction work carried out on or near energised electrical installations orservices is high risk construction work and a safe work method statement must be preparedbefore this work starts.

The following should be considered when working near electric lines:

whether workers, plant, tools or the falsework or formwork are likely to go near electriclines, and if so, how close they are allowed to be

contact the relevant electrical authority for information about specific requirements whenworking near electric lines, including the qualifications required for those people workingnear electric lines

if a safety observer is in place to watch plant when it is moving and is likely to comeclose to electric lines

whether unauthorised person zones, authorised person zones and exclusion zones inthe work area are set up

emergency rescue procedures, including calling the electrical supply authority to isolatethe electricity supply before trying to rescue a person receiving an electric shock.

Most risks can be addressed by observing safe working distances for people working nearelectric lines. Safe working distances will depend on the type of work being carried out and thevoltage of the electric lines. The person conducting a business or undertaking with managementor control of the workplace should contact the relevant electricity supply authority to determinethe type of control measures needed. This may include isolating the line.

More detailed guidance on managing risks associated with electricity is available in the: Code of Practice: Managing Electrical Risks at the Workplace Code of Practice: Working in the Vicinity of Overhead and Underground Electric Lines.

3.8 Securing the work areaR.298:A person with management or control of a workplace at which construction work iscarried out must ensure, so far as is reasonably practicable, that the workplace is secured fromunauthorised access.

In securing the workplace, the person conducting a business or undertaking with managementor control of the workplace should consider:

risks to health and safety arising from unauthorised access to the workplace the likelihood of unauthorised access occurring, e.g. how close the workplace is to

places frequented by children like schools, parks and shopping precincts to the extent that unauthorised access to the workplace cannot be preventedhow to

isolate hazards within the workplace.


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3.9 Emergency plan

R.43:A person conducting a business or undertaking must ensure that an emergency plan isprepared and maintained so it remains effective for the workplace, and provides for thefollowing:

emergency procedures, including:o an effective response to an emergencyo evacuation procedureso notifying emergency service organisations at the earliest opportunityo medical treatment and assistanceo effective communication between the person authorised by the person conducting the

business or undertaking to co-ordinate the emergency response and all persons atthe workplace

testing of the emergency procedures, including the frequency of testing information, training and instruction to relevant workers in relation to implementing the

emergency procedures.

To ensure a co-ordinated approach to responding to an emergency, the formwork or falseworkinstaller should consult with the principal contractor to ensure any unexpected incidents, forexample formwork collapse or people falling from height, are included in the broader emergencyplan for the construction site prepared by the principal contractor.


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4 WORK METHODS AND SYSTEMS

The nature of the formwork and falsework activities will affect the formwork method and a safesystem of work you select.

A range of formwork and falsework systems and methods can be used. However, no matterwhat system or method is selected, the formwork and falsework to be erected and itscomponents should be maintained in a safe and stable condition to prevent the unexpectedcollapse of all or part of the structure.

4.1 Traditional and modular formwork systems

Traditional formwork systems are typically constructed on-site from timber or plywood andsupporting elements like scaffolding.

In addition to traditional systems, modular systems specially designed and manufactured off-siteare also available. These systems usually have proprietary formwork components and ratedload calculations set out by the manufacturer and are often made from hardboard, plastics, steeland aluminium products. Most formwork systems use two or more materials, for exampleplywood facing to steel frames for wall panels.

In choosing a formwork system for a particular job, the safety of workers erecting, using anddismantling the system should be considered, in particular stability, strength and the risk offalling people and falling objects.

When using a traditional system, a standard formwork frame that has a known tested loadingcapacity should be used wherever possible, ensuring that they are spaced at no more than therecommended distances apart. Standard frames can minimise the risk to workers erecting and

dismantling the formwork and handling and storing materials. The best proprietary systemsavailable have integrated safety features to help control the risk of falls and injury during manualtasks.

Where a modular system is used in combination with a traditional system, formwork drawingsshould be certified as complying with applicable Australian Standards. Similarly, componentsfrom another system should not be used as an integral part of the modular framework systemunless the designer of the modular system states this is permitted. All variations to a design of abasic or non-basic system should be checked and verified in writing by a designer, engineer orother competent person as being acceptable.

Modular formwork systems are often lighter weight and require less physical effort than

traditional systems because they are often constructed from aluminium instead of steel andeliminate the need for tasks like repetitive hammering. This minimises the risk of injury resultingfrom undertaking manual tasks. However, because of their lighter weight, modular systems maybe more susceptible to falling over when erecting the system due to factors like wind loading.This will generally only be an issue before placement of the formwork deck on the modularsystem. To effectively control this issue the formwork system should be progressively braced inaccordance with the suppliers instructions during its erection.

Although the erection technique and member dimensions may vary greatly between traditionaland modular systems, application of risk controls associated with the maximum potential falldistance and the gap width at the working level are the same for both systems.


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4.2 Slip forms and jump forms

Slip forms and jump forms are the terms given to self-climbing formwork systems specificallyintended to construct concrete walls and columns in high rise buildings and other concretestructures like stacks, lift and stair cores.

Slip forms and jump forms usually consist of a number of platforms or decks and may also befitted with trailing screens suspended from the form. As with perimeter screens, trailing screensmay provide edge protection for people, prevent materials from falling, provide support for workplatforms or a combination of these. No two slip forms or jump forms will be identical becausetheir design depends on the size and configuration of the building under construction.

In slip forms, the climbing is usually carried out continuously during the concrete pour (seeFigure 3).

Figure 3Slip form chimney construction

With jump forms, the climbing is done in steps, following each concrete pour (see Figure 4). Theterm climb form is also used to describe both a slip form or jump form. The power for theclimbing operation can be provided in a variety of ways, but usually by means of hydraulic ramsor electric motors connected to climbing feet or screw shafts.


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Figure 4Jump form construction

4.3 Travelling formwork

Travelling formwork moves horizontally allowing the repeated construction of structural

elements for example in-situ concrete bridge spans (see Figure 5). The formwork is generallysupported by the permanent structure as it is progressively completed and therefore has theadvantage that no falsework is required over the length of the bridge.

Travelling forms are useful where there is limited capacity to construct falsework, for exampleover rivers and operating roads or railways.


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Figure 5Travelling formwork for bridge construction


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5 FORMWORK AND FALSEWORK ACTIVITIES

The erection and dismantling of formwork and falsework can be critical to ensure the health andsafety of workers and the general public. Systems of work and control measures should be

selected based on individual job factors, the work environment and other factors identified bythe risk assessment process outlined in Chapter 2 of this Code.

5.1 Foundations and footings

Formwork and falsework must, so far as is reasonably practicable, be erected on a stable baseto prevent the risk of collapse which puts the health and safety of workers and others at risk.Check whether suspended slabs are able to safely support loads that may be applied by theconcrete pour, workers and crane lifted loads and other plant and equipment.

Independent props should also be secured to each other and to the structure to preventdislodgement during erection and dismantling.

Base plates should be provided under all props and standards on formwork and falseworkframes unless the prop or standard has an integral foot or a competent person documents abase plate is unnecessary. Sole boards designed to suit the ground conditions should also beused under props and standards on natural ground, unless a competent person documentsotherwise.

Frames and props must, so far as is reasonably practicable, be located on a firm base which isground that will not subside, fail or get washed away.

DrainageAdequate drainage for stormwater should be provided to prevent scouring of formwork and

falsework foundations and footings. Where foundations are located on batters, these should beprotected against scour by directing drainage away from the base of frames.

5.2 Erecting formwork and falsework

Formwork and falsework, like scaffolding, should be erected and dismantled systematically by acompetent person and tied in progressively to stabilize the structure. Prefabricated formworkand falsework should be erected and used in accordance with the manufacturers instructions.

Where scaffolding is used to erect formwork and falsework it must comply with the requirementsfor scaffolding, including using licensed scaffolders. A licensed scaffolder is required where aperson or object can fall more than 4 metres. Further guidance is available in the Code ofPractice: Scaffolding Work.

Entry and exitSo far as is reasonably practicable, workers must, so far as is reasonably practicable, beprovided with safe entry to and exit from the formwork and falsework during erection, use anddismantling. Common ways of providing safe entry and exit for large or complex formwork andfalsework structures include:

installing temporary stairs or portable ladder access systems for use when erecting theformwork and falsework

personnel hoistsnon-mechanical forms of exit, e.g. a ladder or stair tower should beprovided in case of emergency

installing permanent stairs, platforms or ramps

using the existing floor level of a building, where entry is safe.


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The false deck should be constructed so there are no large gaps and gaps only exist where avertical member of a frame passes through the deck (see Figure 6). Gaps should not exceed225 mm in width.

Figure 6 Plan view of a false deck with gaps at vertical framing members.

Where a false deck is provided, it should designed and installed to have adequate strength tosupport people required to stand on the deck and any materials or people that could fall ontothe deck or be placed on the deck.

When considering the design of the deck for the erecting, altering or dismantling of formwork,

the weight of the false deck and live load should be applied to the formwork support structure.

The height between the false deck and the pouring deck should allow entry for a person duringstripping. Workers must take reasonable care for their own safety by not climbing theframework.

Intermediate platformsWhere the potential fall distance is less than 2 metres, an intermediate work platform can beprovided that is at least 450 mm wide (see Figure 7).

Installing bearersBearers should be placed in position so people are located no more than 2 metres from the floor

or from the fall arrest platform located immediately below them. For example, the bearer can belifted up onto the top of the formwork frame U-heads with a person standing on a platformerected no more than 2 metres from the floor or false deck located immediately below themwithin the frame.

Bearers should be positioned so they will not fall off the top of the frames. The usual method ofensuring this is by placing the bearers in U-heads on top of the frames and by ensuringcantilevers are minimised. U-heads should be used where two bearers abut. Where only singlebearers are placed in the U-head, the bearer should be placed centrally in the U-head unless aformwork designer, engineer or other competent person states otherwise. This can be achievedby rotating the U-head or by using timber wedges.


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Where the top of the supporting member consists of a flat plate, the bearer should be nailed orotherwise effectively secured to the plate. Flat plates should only be used where specified by aformwork designer, engineer or other competent person.

Installing joistsWhere a false deck is provided at 2 metres or less below a worker, joists may be spread on thebearers with the worker standing at bearer level, that is, on top.

If the height of the formwork deck being constructed is more than 2 metres above a continuousdeck or surface below it, joists should be spread from a platform located within 2 metres of thatsurface, underneath the deck being constructed (see Figure 7). This work platform should be afalse deck but an intermediate platform may be used.

Figure 7 Worker erecting formwork from an intermediate platform less than 2 metres above aformwork deck where the deck to deck height is greater than 2 metres

A person should be provided with a working platform at least 450 mm wide (2 planks) when thepotential fall distance is less than 2 metres. It is not acceptable for a person to work from asingle plank or bearer.

One example of a work system that may be used to do this is as follows:

The joists are lifted by the workers from underneath and spread on top of the bearersinto their approximate final positions whilst standing on a lower work platform.

The platform below the deck should be positioned at a height appropriate forhandling joists, without introducing manual task risks, and not greater than 2 metresabove the continuous deck or surface below.

Fall protection from the formwork deckDuring formwork construction the structure is constantly changing so continual modification offall protection measures is also necessary.

When there is only one leading edge where the other edges are provided with scaffold edgeprotection or safety screens, providing fall protection on the leading edge is relatively


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straightforward. However, where there are multiple leading edges or the deck is not at oneconsistent level, providing fall protection may be difficult to implement. Designers of buildingsare therefore encouraged to design floor slabs with consistent thickness.

Edge protection on the formwork deckWhere the design of the formwork is complex, it may be impractical to provide edge protectionon leading edges because the profile of the deck is constantly changing and constructingleading edge protection would create more hazards than it would control. For example, thepeople installing the edge protection could be exposed to risk when installing the edgeprotection.

In some situations it may be necessary to provide perimeter edge protection on edges of theformwork deck. Examples where edge protection should be installed are:

if there is a change in deck height along the side of the deck being constructed, i.e. adrop down for a beam, and no joists or formply has been provided at this differentheight

if a leading edge is to be left unattended and entry onto the deck by people other

than form workers is required, i.e. the formwork deck has not been barricaded offand provided with keep out signs at openings in stairwells or lift shafts.

An effective means of providing edge protection on a completed formwork deck is by providingperimeter containment screens (see below) or a scaffold. Scaffolding is erected before theformwork and prevents workers falling off the completed deck. The main advantage of thesesystems is that people are not required to install edge protection on the perimeter of theformwork deck and are therefore not exposed to a risk of falling. The other advantage is thatedge protection for people installing the final perimeter formply sheets is already in place.

Where suspended, cantilevered, spur or hung scaffold, or any scaffold from which a person or

object could fall more than 4 metres from the platform or the structure is used, any erection,alteration or dismantling of the scaffold must only be carried out by licensed scaffolders. It isimportant to replace scaffold components following removal so as not to affect the structuralintegrity of the scaffold. Cover gaps between a completed floor and scaffold after the formworksupport system is removed where there is a risk of a person or materials falling through the gap.

In rare situations, it may be impractical to provide perimeter containment screens or scaffolding.Use a work system to install perimeter edge protection on the deck which eliminates orminimises, so far as is reasonably practicable, the risk of a fall. Harness systems should not beused because it does not provide an adequate and practical control for the risk of a fall fromheight.

In some situations, edge protection can be substituted with an alternative measure provided thismeasure prevents a person falling from the edge. One alternative is providing a barricade 1.8metres back from the edge with clearly visible warning signs.

Perimeter containment screensPerimeter containment screens are protective structures fixed to the perimeter of a multi-storeybuilding, structure or working platform to prevent objects and people from falling outside thework area. This significantly minimises the risk of injury to workers and the public.

Screens should be used throughout the whole construction process, especially while erecting or

stripping formwork. They are usually sheeted with timber, plywood, metal or synthetic mesh.


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Containment screens may be supported by the building or structure or by specifically designedscaffold. The screens can also act as perimeter fall protection on a top working platform andshould extend at least 2 metres above the working surface to provide protection for the publicand workers outside the contained work area.

When selecting containment screens consider: the ability to support or contain imposed impact loads, including building materials,

equipment and waste materials resistance to wind loads on the supporting structure required frequency of inspection chemical reactivity, including flammability ventilation requirements light transmission requirements degree of protection provided from rain or washing down operations pattern and frequency of fixing points gaps created by a fixing method.

Containment screens should remain in position from the start of the formwork being erecteduntil soffit stripping is complete to prevent objects falling throughout the process.

To prevent material from falling below, gaps between perimeter screens and the formwork deckor floor should not exceed 25 mm.

Laying formply on the deckA formwork deck should be laid in a progressive way so people will be provided with a methodto prevent them from falling below the deck. This control measure is particularly important insituations where a false deck has not been provided within 2 metres below the level of the deckto be laid.

Where a false deck has not been provided within 2 metres below, formply may only be spreadon the joists provided where:

people start laying the formply sheets from the perimeter scaffolding or other edgeprotection provided on the perimeter of the formwork

a minimum of four joists at 450 mm centres400 mm gaps, totalling 1.8 metresarelocated on bearers next to the person and in the other direction joists extend for at least1.8 metres (see Figure 8). Therefore, if a person falls they will fall onto the joists andshould be prevented from falling further. In some situations, there may be a possibility ofa person falling through the joists if the joists spread as the persons body makescontact. This is more likely to be a potential hazard when the person falls onto the joists

so the persons fall is in the same direction as the joists. Implementing controls tominimise sideways movement of joists will minimise this possibility.

People lay the formply in front of their bodies so if they stumble they are likely to fall ontop of the sheets being laid.


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Figure 8 Maximum spacing of timbers where deck is over 2 metres below

Where a leading edge is involved and the distance below the deck being constructed is greaterthan 2 metres the safe work method statement work must detail how work will be completed tocontrol the risk.

CantileversCantilevered bearers, joists and ply sheets can be hazardous when left unsecured. The weightof material or a person standing on the cantilever may make the timber see-saw and cause theperson or material to fall. When designing the formwork system using cantilevers should be keptto a minimum. However, in some situations using cantilevered sections is unavoidable. Wherethis is the case, a formwork designer should consider the potential for people and storedmaterials to cause cantilevers to pivot. Wherever the weight of a person will cause a cantileverto pivot, the cantilever should be positively secured so this will not occur.

Where self-weight of timber is inadequate to ensure the stability of the cantilever, all cantileversshould be secured in accordance with the designers instructions. This may include nailing or

another effective method, for example bolting. Nailing should be carried out so the nail will notpull out of the timber or shear off. Where skew nailing is used a minimum of two nails should beused and the nail should meet the designers specifications.

Wherever practical, cantilevers should be secured so the nail or bolt is loaded in pure shear,that is, no pull-out load. Using purpose designed brackets should also be considered.

Materials should not be stacked or stored on a cantilever section unless the section has beendesigned to carry that load. Temporary working platforms cantilevered from shoring frames area form of cantilevered scaffold. Where a person or object could fall more than 4 metres from ascaffold, workers involved in erecting, altering or dismantling them must hold a valid scaffoldinglicence. The minimum licence class for this type of work is Intermediate Scaffolding.


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Figure 9End view of deck showing working zones

Changing f loor levelsFormwork decks are rarely flat across the entire floor, generally due to deep beams or dropdowns sometimes called capitals around columns. Uneven floors introduce fall hazards. Thesehazards should be eliminated at the design stage. These hazards are most effectively managedby ensuring formwork supports and the deck are progressively constructed for the lower parts ofthe deck before work starts on the higher-level areas of the deck.

5.4 Crane and load handling

Lifting and placing loads is a common formwork and falsework activity that can havecatastrophic consequences if not managed appropriately. Designers should consider the worksystems that may be used so formwork and falsework structures are designed to be capable ofcarrying temporary loads during construction and dismantling, as well as the load of thepermanent structure.

Loading materials during construction

Plant and materials, including propping members, stacks of plywood, forms, bearers and joists,are sometimes lifted onto a deck during formwork and falsework erection, and before the deckis inspected and determined safe by a competent person. Stacked materials create pointloadings which the formwork or falsework structure may not be designed to bear.

Plant and materials should only be stored on formwork and falsework where allowed for by thedesign and when the structure or deck is constructed to bear the load.

Formwork is not suitable for any loading until it is fully secured. That is, when the deck is inplace with tie-ins and back-propping is complete. In practice, some loading often occurs before


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5.5 Inspecting and monitor ing

A competent person, for example an engineer with experience in structural design, shouldinspect and confirm installed formwork and falsework is built to specification and structurallysound before it is loaded, for example with materials or the placement of concrete. The scope ofthis certification work should be documented so there is no confusion or doubt what has been

inspected.

The erected formwork and falsework should not be subjected to any load until it has beenconfirmed as meeting the design specification, for example pre-pour inspection. The erectedformwork and falsework should not be subjected to any loading exceeding the design loading asspecified by the designer. To maintain stability of the forms the placement of concrete should beless than the maximum calculated pour rate on the inboard part of any formwork beforeproceeding to any cantilever section.

Formwork and falsework should be monitored as it is loaded to check that vertical andhorizontal movements do not exceed specifications. The condition of falsework that is to remainin service for long periods should be routinely checked to ensure its components remain fit for

purpose and any deterioration is not adverse

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