Upload
tino3528
View
237
Download
0
Embed Size (px)
Citation preview
8/22/2019 Formwork Guide
1/37
INDUSTRY GUIDE
FOR FORMWORK
CONSTRUCTION INDUSTRY SOUTh AUSTRAlIA
JUNE 2012
8/22/2019 Formwork Guide
2/37
1
INDUSTRY GUIDE
FOR FORMWORK
8/22/2019 Formwork Guide
3/372
Awdt
This guidance material has been developed by a tri-partite industry
working party and has involved extensive consultation with industry
and other special interest groups. The contribution of the following
organisations is acknowledged:
BuiltEnvironsPtyLtd
Construction,Forestry,MiningandEnergyUnion
HansenYunckenPtyLtd
HindmarshAustralia
MitconFormworkPtyLtd
NewgenFormworkers
SystemFormworkPtyLtd
SafeWorkSA
Diaa t :
BovisLendLease
WorkplaceHealthandSafetyQueensland
SafeWorkSA
Phtaph t :
Construction,Forestry,MiningandEnergyUnion
MitconFormworkPtyLtd
SystemFormworkPtyLtd
HindmarshAustralia
Diai
Information provided in this publication has been prepared by industry
representatives and is designed to prevent injury to anyone engaged in
erecting and dismantling formwork and associated equipment.
This publication is correct at the time of printing and is provided as general
information only. In utilising general information about workplace health
andsafety,thespecicissuesrelevanttoyourworkplaceshouldalwaysbe
considered.
Theremaybeadditionalrisksataworkplacethathavenotbeenspecically
addressedinthisguidance.UndertheSouthAustralianoccupational
healthandsafetylaws,suchrisksmustbeidentiedandcontrolmeasures
implemented and reviewed to eliminate or minimise exposure to these risks.
Usersofthisguidancematerialshouldbeawarethatitisbasedoncurrent
knowledge and construction methods within the industry and is not intended
to exclude other methods or processes that can also meet the required
safetystandards.Thisindustryguide,onanyparticularaspectoflegislation,
is not to be taken as a statement of law. To ensure compliance with your
legalobligationsyoumustrefertotherelevantActs,Regulationsand
ApprovedCodesofPractice.Thispublicationmayrefertolegislationthathasbeenamendedorrepealed.Whenreadingthispublicationyoushouldalways
refer to the latest laws.
PrefAce
ThisIndustryGuideforFormworkisbasedontheSouth
AustralianOccupational Health, Saety and Welare
Regulations 2010.GiventhatSouthAustraliaislikelytoadopttheharmonisedlegislation,itisrecommended
that readers of this document also become familiar with
therequirementsoftheWorkHealthandSafety(WHS)
legislation once it comes into effect.
SafeWorkSA,incollaborationwithmembersofthe
ConstructionIndustry,hasproducedthisguidanceto
provideemployers,self-employed,andemployeeswith
practical advice on preventing injury to anyone engaged
in erecting and dismantling formwork and associatedequipment.
AspartoftheSAConstructionIndustryOHSCommittees
strategytoaddressareasofhighrisk,itwasagreed
that the creation of appropriate industry guidelines for
erecting and dismantling formwork and associated
equipment was a priority.
It was further agreed that the codes of practice and
guidelines,existinginotherstates(Queensland,NewSouthWalesandVictoria)andoperatingeffectively,could
be utilised in the development of a similar resource for
SouthAustralia.
Th ti thi idt id a t:
givepracticaladviceaboutwaysto
aa xp t i aiatd
with w ii th a,
ti, atati ad diati
w
contributetothedevelopmentof
itt hih tadad a w
i th tti idt that
a di t t pati at
th wpa.
It i t itdd that thi id appid t
i-t hi.
8/22/2019 Formwork Guide
4/373
conTenTs
1. Itdti 4
1.1 Fallsfromheightlimitationsofharness 4
systems for formwork activity
2. Di 5
2.1 Safedesignofbuildingsinrelat iontoformwork 5
2.1.1 Buildability 5
2.1.2Materials 5
2.2 Formworksystems 6
2.2.1 Safeformworkdesignandverication 6
2.2.2Formworkdesigncerticationrequirements 6
2.2.3 Documentation 7
2.2.4 Designvariations 8
2.2.5 On-sitecoordinationandverication 83. cdiati ad adiitati 9
3.1 Workprogram 9
3.2 Housekeepingaccessandstorage 9
3.2.1 Accessandegress 9
3.2.2Materialstorage 9
3.2.3 Rubbishstorageandremoval 9
3.2.4 Storagetominimisemanualtaskrisks 9
3.3 Training 10
4. W t 10
4.1 Formworkerectiontraditionalsystems 10 4.1.1 Foundations 11
4.1.2 Falsedeck 11
4.1.3 Erectingframes 11
4.1.4 Installingbearers 12
4.1.5 Installingjoists 12
4.1.6 Fallprotectionfromtheformworkdeck 12
4.1.7 Edgeprotectionontheformworkdeck 13
4.1.7.1 Formworkconstructionzonephysicalbarriers 13
4.1.7.2 Edgeprotectiononcompleteddecks 13
4.1.8 Layingaformworkdeck 13
4.1.8.1 Gettingstartedsafeaccess 13
4.1.8.2 Typicalworksystemforaleadingedge 15
4.1.8.3 Layingaformplydeck 15
4.1.8.4 Layingametaldeck 16
4.1.9 Cantileverrequirements 16
4.1.10 Penetrations 16
4.1.11 Workingzonesforformworkersandothers 17
4.1.12 Changingoorlevels 18
4.2 Formworkerectionmodularformworksystems 18
4.2.1 Basicmodularsystems 18
4.2.2 Training 18
4.3 Strippingformwork 18
4.3.1 Generalformworkstripping 18
4.3.2 Safeworkmethodstatements 18
4.3.3 Certicationpriortostripping 19
4.3.4 Exclusionzone 19
4.3.5 Dropstripping 19
4.3.6 Bondreduction 19
4.4 Craneandotherloadhandlingsystems 19
4.4.1Loadingmaterialsduringformworkconstruction 19
4.4.2 Slingingloads 19
4.4.3 Liftinggear 20
4.4.4 Liftingformworkmaterials 20
4.4.5 Liftinglugs 20
4.5 Useofladders 20
5. spia qit wa ad 21
5.1 Bracingforwindloading 21
5.2 Accessplatforms 21
5.3 Liftingmethods 21
6. spia qit ip ad p 22
6.1 Accessandegress 22
6.2 Workplatforms 23
6.3 Trailingscreensandplatforms 23
6.4 Climbingtheform 23
6.5 Training 24
6.6 Healthissuesandamenities 24
6.7 Engineeringissues 24
6.8 Emergencyissues 25
7. fai t 26
7.1 Hazardcontrols 26
7.2 Preventtheobjectfromfalling 26
7.3 Perimetercontainmentscreens 26
7.3.1 Screenheightatbuildingstep-ins 26
7.3.2 Perimeterscreengaps 27
8. Hath 27
8.1 Noise 27
8.2 Dustandatmosphericcontaminants 28
8.3 Manualtasks 28
APPenDIces 29
Appendix1:Denitions 29
Appdix 2: Taii 30
Appendix3:Sampleengineerscerticationletters 31
Appdix 4: ctti hit 33
Appendix5:Samplestructural(pre-pour)certicate 34
Appdix 6: Dt d i 35
w t
8/22/2019 Formwork Guide
5/374
1. Itdti
Formworkisthesurface,supportsandframingusedtodenethe
shapeofconcreteuntiltheconcreteisself-supporting(seeAS 3610-
1995 Formwork or Concrete).
Forthepurposesofthisguide,theformworkassemblyincludes:
theformsonwhichconcreteispoured
thesupportstowithstandtheloadsimposedbytheforms
and concrete
anybracingaddedtoensurestability.
Hazardsassociatedwiththeerection,alterationordismantlingof
formwork include:
fallsfromheight
fallingobjects
formworkcollapse(before,duringandafterpouringofconcrete)
slipsandtrips
noise
dust
manualtasks
sharpedgesonmetaldecks
sunglare.
Toproperlymanagerisks,apersonmust:
identifyhazards
assessrisksthatmayresultbecauseofthehazards decideoncontrolmeasurestoprevent,orminimise,
the level of risk
implementthecontrolmeasures
monitorandreviewtheeffectivenessofthosemeasures.
Controlmeasuresmustbeimplementedinanorderofpriorityand
beforeworkcommences.Figure1belowillustratesthehierarchy
of controls which represents the order of priority for controls where
there is a risk that a person could fall.
1.1 fAlls from HeIgHT lImITATIons of HArness
sysTems for formWork AcTIvITy
Whenerecting,alteringordismantlingformwork,theuseofthe
following systems is not recommended:
travelrestraintharnesssystemstopreventafall fallarrestharnesssystemstoarrestafall.
Travel restraint harness systems are impractical for formwork as:
thecontouroftheleadingedgeisconstantlychanging,requiring
the length of the travel restraint line to be continually adjusted
multiplelanyardanchoragepointsmayberequired
thegreaterthenumberofworkersbuildingtheformworkdeck,
the greater the likelihood of lines becoming tangled.
Fall arrest systemsareprohibitedundertheSouthAustralian
Occupational Health, Saety and Welare Regulations 2010(OHSWRegulations)insituationswherethereisinsufcientdistance
availabletopreventapersonhittinganobject,thegroundoranother
surface,otherthanaverticalsurface.Forexample:
Whenerecting,alteringordismantlingformwork,theremaybe
insufcientfreefalldistanceunderneaththeworkingarea,
resultinginafallingpersonstrikingtheground,aframeorother
obstruction prior to the fall being arrested.
Afallingpersonmayrequireafreefalldistanceinexcessof
6mforthefalltobesafelyarrestedbyaharnesssystem.In
somesituations,thisdistancecanbesubstantiallyreducedbythe use of shorter lanyards and/or higher anchorage points.
Theanchoragepointdesignloadrequiredforfallarrestsystems
isrelativelyhigh.TheOHSWRegulationsspecifythateach
anchorage point of the system must have a minimum capacity of
15kNforonepersonfree-falling.
Theerectionofformworkframesusingfallarrestharnesses
requires the user to regularly disconnect from and reconnect to
anchoragepoints,requiringtheuseofadoublelanyard.
Figure 1 Hierarchy o controls Controlling the risk o alls
Di ad pai
Eliminatetherisk
during the design and
planning stage.
Wh thi i t patia,
1 t:
Workonasolidconstructionwithsafeaccess/egress,edgeprotection,openingscoveredetc.
Wh thi i t patia,
2 t:
Usefallpreventionsystemse.g.temporaryworkplatforms,scaffolds,perimeterguardrails,elevating work platforms.
Wh thi i t patia, 3,
thenlevel4ornally,level5controls:
l 3useworkpositioningsystems,
travel restraint systems
l 4usefallarrestorcatchplatformsl 5useladdersoradministrationcontrolse.g.nogoareas,permitsystems,safe work systems.
8/22/2019 Formwork Guide
6/375
cid th wi i a ha t:
Ariskassessmentaddressingthehierarchyofcontrolsshouldbe
usedtoidentifysatisfactoryalternativestoaharnessbasedon
fall prevention measures.
Implementingtheuseofsolidworkzonebarriersisone
effectiveengineeringsolution.Refertosection4.1.7ofthisguide
for further information.
Trainingisrequiredbeforeapersonusesaharness.Fortraining
requirementsundertheSouthAustralianOccupational Health,
Saety and Welare Act 1986(OHSWAct),pleasereferto
Appendix2.
2. Di
Undersection23aDutiesofdesignersandownersofbuildingsoftheOHSWAct,designersofbuildingstobeusedasworkplaceshave
obligations for workplace health and safety.
2.1 sAfe DesIgn of buIlDIngs In relATIon To formWork
2.1.1 bidaiit
Buildingdesigners,includingengineersandarchitects,must
considerthebuildabilityofastructureorbuildingwiththeobjective
of producing a design that minimises the risk of injury during
construction.
Thedesignofthenalconcretestructuremayhaveamajoreffectontheeaseofformworkconstructionandconsequently,onthesafetyof
peopleduringconstruction.Generally,amorebasicandsimplenal
concrete structure is safer to erect.
Aformworkdesignershouldbeconsultedduringthedesignofany
building to provide input on ways to minimise the risk of injury arising
from formwork activities.
The following design measures could be considered to minimise
exposure to risk of injury during the construction of formwork:
Reducevariationsintheoordepthi.e.constructaoorsothat it has one consistent depth. Decks that are a consistent
depthareeasiertoerectthanvariabledepthoorsandreduce
theriskofinjury.Deeperbeamsintroducedropdownsinto
theoor,creatingtripandfallhazards,andrequiremoreworkto
construct and strip after pouring.
Wherebeamformsareessential,lightweighttemporaryaccess
across the beam recess must be provided to prevent injury to
workersfromsteppingintotheformduringconstruction(see
Figure2above).
Reducethenumberofcolumnsrequiredandwherecolumnsdo
exist,eliminatecapitalsanddropdowns.
Utiliseprecastcolumnsandbeams.Thiscanreducetherisks
associatedwithxingreinforcement,erectingandstripping
columnformworkandpouringconcreteon-site.Workactivities
carried out in a factory environment are generally lower risk.
Reducecantileveredoorsections.
Planformanualtasks.Considerationshouldbegiventothe
suitability of the design of different formwork systems that willreduce manual handling risks such as:
- table forms
- systems with lighter weights of materials to be handled
- methodsofformworkerection,alterationanddismantling
- improved access and egress for workers and movement
of materials and equipment
- methodsformovinglargeandheavycomponents,materials
and equipment i.e. making allowances for a crane and other
mechanical lifting devices to be used.
2.1.2 matia
Allmaterialsandequipmentusedinformworkconstructionmust
betfortheintendedpurpose,meetdesignspecicationsandbe
designedtoconformtorelevantAustralianStandards.Equipment
must be manufactured in accordance with a quality assurance
systemthatensurescompliancewiththedesignspecication.
Evidenceverifyingthatformplysheetsandtimberbearersconform
toAustralianStandardsshouldbekepton-site.Suchevidencemay
include:
apurchaseorderwhichdetailsthespecicationsofthe
form ply sheets ordered
formplysheetsbeingmarkedinaccordancewithAustralian
Standards(seeAS/NZS 2269.0:2008 Plywood-Structural-
Specifcation).
Figure 2 Flat oor and temporary access as
all protection or deep oor beams
8/22/2019 Formwork Guide
7/376
Ifalternativeproducts,otherthantimberareused,anengineer
should verify that they are adequate for purpose.
2.2 formWork sysTems
InAustralia,formworksystemsaregenerallydesignedto:
AS 3610 Formwork or Concrete
AS 3600 2009 Concrete Structures.
2.2.1 Safeformworkdesignandverication
Adesignerofformwork,eitheraformworkdesigneroranengineer
(seeAppendix1fordenitions),isresponsibleforoverseeingthe
safe design of the complete formwork structure. This includes
designoftheformworksupportstructure,theformworkdeckand
connection details.
Whenspecifyingthedesignoftheformworksystem,aformworkdesigner must allow for all expected loads applied during the three
phasesofconstructioni.e.duringformworkerection,duringconcrete
pouring and after concrete pouring is complete until the structure is
self-supporting. This includes loads applied by:
theformworkdeck,supportingmembersandformworkframes
anyfalsedecksthatmaybeprovided
concretepouringtechniques(i.e.concreteskiporpump)
theconcretepour,whichincludesboththeweightofthe
concreteanddynamicfactorsapplied,includingtheconcrete
pour rate and pour sequence workersontheformworkdeckandfalsedecks
stackedmaterials
crane-liftedmaterialsonboththecompleteandincomplete
formwork deck
environmentalloads,includingforcesduetowaterowing
aroundtheformwork.Rainandrunoffcanhaveadetrimental
effect if not considered by a designer
wind,asdetailedinAS 1170.2:2011 Structural Design Actions
Wind Actions:
wind loading will vary depending on:
- thesizeofform
- the nature of the form
- wind speed
- windresistance(e.g.screens)
- wind direction
windloadingonverticalforms,particularlyforexternalwalls,
columns,freestandingshutters,bladewallsandany
platforms that may be subject to uplift
vertical elements should be fully braced prior to and during
stripping until such time as the construction provides
adequate support against wind loading shadeclothusedonscreens,signageandoutsidescreens
will increase the effective wind loading of an open structure
the geographical location of the construction site will have a
bearingontheseverityofwindonthestructure.Wind
generally has less effect in built up or hilly areas
AS 1170.2 Structural Design Actions Wind Actions
speciesfourdifferentterraincategoriesthatshouldbe
taken into consideration by a formwork designer as well asbasicwindspeedsfordifferentzonesinAustralia
[practicallyallareasofSouthAustraliafallunderRegionA
(normal)].
Refertosection4StructuralDesignandDocumentationof
AS 3610 Formwork or Concretefor further details on formwork load
calculations.
2.2.2 Formworkdesigncerticationrequirements
This guide considers two types of formwork systems: ai and-ai.Aformworkdesignermaycertifyabasicformwork
system,whereasonlyanengineermaycertifyanon-basicformwork
system.
Whilethisguiderecommendsthatonlyanengineermaycertifya
non-basicformworksystem,itisrecognisedthatacompetentperson
experiencedinformworkdesignanddocumentation,suchasa
formworkdesigner,mayperformthemajorityofthedesignwork.
Forbothbasicandnon-basicformworksystems,certicationshould
conrmthattheformworkmeetstherequirementsofAS 3610
1995 Formwork or Concreteand the construction drawings. Thiscerticationshouldalsoconrmthatotherformworkandproject
documentationdetailedinsections2.2.3ofthisguide,havebeen
completedasrequiredfortheproject.Sampleengineerscertication
lettersareprovidedinAppendix3.
bai w t
Forthepurposesofthisguide,abasicformworksystemisthe
formworkforaoor,wallorcolumnandincludes:
standardformworkframeswhichhaveaknowntestedloading
capacity and are spaced at no more than the recommended
distancesapartforanormaloorthicknesswithbearers,joists
and form board on top of them
speciallymanufacturedanddesignedformworksystemswith
proprietary formwork components and rated load calculations in
linewiththemanufacturersspecications.
Abasicformworksystemislimitedbythefollowingconditions:
theheightoftheformworkmaybeuptoamaximumof6mto
thesoftofthenewoorfromthesupportingoor
wallsandcolumnsmaynotbegreaterthan6mfreestanding fromtheooronwhichtheformworkwillbesupportedtothetop
surface of the concrete
anyback-proppingisexcludedfrombasicformworksystemsand
istobecertiedbyanengineer.
8/22/2019 Formwork Guide
8/377
Eitheraformworkdesignerorengineermaycertifyabasicformwork
system.Whereanyoftheseconditionsareexceededorback-
proppingisinvolved,thesystemistobeclassiedasanon-basic
formworksystemandmustbecertiedbyanengineer.
n-ai w t
Formworksystemsthatexceedthedescriptionofabasicformwork
systemare,forthepurposesofthisguide,categorisedasnon-basic
formworksystems.Forthepurposesofthisguide,onlyanengineer
may certify:
thedesignofanytemporaryorpermanentformworkstructures
categorised as non-basic formwork systems
anyback-proppingusedforeitherbasicornon-basic
formwork systems.
Non-basicformworksystemsincludeformworkstructuresforany
oor,wallorcolumnhigherthan6m,orthreeframes,orthreetimesthe least base width of the scaffold.
2.2.3 Dtati
The extent of documentation required for any structure may vary
depending on the complexity of the formwork and supporting
structure design and the conditions in which it is to be constructed.
The documentation requirements outlined below are provided as
aguideonly,forsituationswherethereisacomplexconstruction
processatheight,thatisconsideredtobehighrisk.Itisexpected
that some elements of documentation may be reduced or omitted forsome more basic and lower risk construction applications.
fw dawi
Formworkdrawingsexplainthegeneralarrangementoftheformwork
plans,elevationsandsections,identifyingandlocatingallmembers
and components including bracing.
Anengineershouldnominatethefollowingonthedrawingsorother
documentation:
maximumallowablepointloadingtobeappliedandany additionalproppingrequirementsatanyspecicloadingarea
componenttypesandspacing
maximumjackextensions
bearerandjoisttimbertype,dimensionsandspacing
propsizesandmaximumextensions
methodsfortyingthestructuretogetherandspacingbetween
ties(ifrequired)
formplysize,thicknessandgrade.
WhereeccentricloadingistobeappliedtoU-heads(i.e.single
bearersarepositionedtoonesideoftheU-head),theformworkdrawings must state that this is permitted.
oth w dtati
The following information should be included in the formwork
documentation:
anynecessarypreparationofthefoundationsuchaslling,
compaction and drainage anyfootingdesignassumptions,suchasfoundationmaterial
description,safebearingvalues,limitationsonsettlementduring
erectionofformwork,placementofconcreteanddismantlingof
formwork.Referencetoinformationsourcessuchas
geotechnical reports may also be included
footingdetails,suchastypeandsizeoffootings,levelofsoft,
concretemixdesignstrength,reinforcement,specication
anddetailsofsitellingorcompaction,andprecautionsagainst
washouts
sufcientdetailstofullydescribeimportantorunusualfeatures
oftheformworksystemdesign,includingdesignassumptions,
particularlythoserelatingtostrength,stabilityandstiffness
theareasoftheformsdesignedtocarrystackedloads,together
withthemaximumallowableload,andtheminimumstrengthof
concrete to be achieved prior to materials being stacked
Safeworkmethodstatementsaddressing:
the erection and stripping of the formwork assembly
methods for securing single or multiple props
methodsforeldadjustmentoftheformspriortoand
during concrete placement
verticalpourratesinmetresriseperhour,includingtherisksand implications of exceeding vertical pour rates
sequenceofconcreteplacement,includingdirectionof
intendedpouronrakingorslopingsurfaces(e.g.carpark
ramps and minimum elapsed time between adjacent
placements)
wrecking strips and other details relating to stripping of
the forms
certicationofnon-proprietaryequipment
referencetodocumentationforproprietaryitems
whererequired,locationofweepholes,vibratorholes,clean-out
holes and inspection openings acceptancecriteriaforsingleuseformwork.
Pt dtati
Otherprojectdocumentationshouldincludethefollowing
information:
detailsoffallandedgeprotectioni.e.perimeterscaffolding
locationofanymandatoryjointsandanyspecialproceduresfor
locating other joints
detailsofanyinserts,waterstops,speciallyformedshapesor penetrationstobeconstructed,thelocationanddetailsofwhich
are critical to the serviceability of the permanent structure
informationonanyarchitecturalorstructuralcomponentdetails
to be cast into the structural concrete
8/22/2019 Formwork Guide
9/378
detailsofthecamberingofanyslabsorbeams
informationaboutanypermanentformworksystems,together
withlimitationsondeectionsandanyspecialrequirementsfor
their erection and concreting
limitationsontheuseofthepermanentstructurefortherestraint
of formwork minimumstrippingstrengthortimes,strippingproceduresand
requirements for health and safety
detailedinformationontheeffectofpreorpost-tensioning
procedures on the formwork and any special procedures to be
adopted in the stripping of formwork
detailsofback-proppingthatmayberequiredandminimum
timeintervalsbetweenconcretepours,includingrequirements
for propping of any composite construction
requirementsfortheminimumnumberoflevelsofsupports
relativetothetypeofformwork,thetimingandsequenceof
oorpropping,andtheanticipatedtimebetweenconstructionof
subsequentoorsformultistoreystructures.
2.2.4 Di vaiati
Allformworksystemdesignvariationsmustbecheckedbyaformwork
designerforabasicsystem,oranengineerforanon-basicsystem.
Thevariationsmustbecertied(inwriting)ascomplyingwith
AS 3610 Formwork for Concreteor whether they need to be altered
in accordance with written directions to comply withAS 3610.
Potentialvariationsmayinclude:
thenumberofformworkframesundertheformworkdeck
typesandnumberofbracesorpropsotherthanindicatedon
the formwork drawing
typesand/orquantitiesoftiesontheformworkstructure
spansonmemberssupportingtheformworkdeck
back-proppingsystemsspeciedbyanengineer
connectionsbetweentraditionalformworkand
modular formwork.
2.2.5 On-sitecoordinationandverication
Complexprojectsrequireconstantandvigilantcoordinationbyan
experiencedmanagementandsupervisoryteam.Withproperly
scheduledandcoordinatedactivities,sub-contractorsareabletocarry
outtheworkinanorderly,safe,andmoreproductiveway.
Effectivecoordinationandtechnicalaccuracyalsorequirethat
formwork,projectandvariationdocumentationarereadilyaccessible
on-site.
Wheneffectivesitecoordinationisnotimplementedoraconstruction
teamdoesnothaveaccesstoessentialtechnicalinformation,the
potential for failure increases.
Vericationoftheformworkstructure
Aneffectivequalitycontrolsystemmustbeimplementedforthe
construction of formwork. The system should ensure that:
materialsandcomponentsusedon-sitecomplywiththeformwork
designspecications,drawingsanddocumentation
damagedorexcessivelywornmaterialsandcomponentsarenot
used,butareidentiedandsentoff-siteforrepairoraredestroyed.
Theformworkstructurescompliancewithitsdesignmustbeveried
anddocumented.Aconstructionchecklistmaybeusedasaguidefor
thisprocess(refertoAppendix4forasamplechecklist).However,
relying solely on a checklist does not necessarily verify compliance with
relevantAustralianStandards.
Thedesignvericationanddocumentationprocessmaybedelegated
toacompetentpersonwho,ifnotanengineerorformworkdesigner,
musthavetheexperience,trainingandknowledgetoperformon-site
inspectionsoftheformworksystem(refertoAppendix1fordenitions).
The competent person must be:
experiencedinformworkconstruction
competentininterpretingdrawings
abletocertifythattheformworkstructuresatisesthedetails
ontheformworkdrawings,specicationsandanyotherformwork
documentation.
Shouldthecompetentpersonon-sitenotbeaformworkdesigneroran
engineer,thecompetentperson:
mayonlyverifythattheformworkstructurecomplieswiththe
designersspecicationsanddrawings
maynotauthorisevariationstothedesign mustprovideanyconstructionchecklistreferralstoanengineer
in writing
mustprovidewritteninstructionstotheformworksupervisorfor
any remedial actions that need to made to the formwork system
prior to the concrete pour
mustensurethatanyremedialactionrequiredhasoccurredprior
totheconcretepour,includinganyitemsreferredtoanengineer.
Pre-pourinspectionmustfocusonsuchmattersas:
thelatestversionofstructuralandformworkarrangement
drawings and details submitted
correctspacingofframes,propsandtimbers
correctjoistandbearersizes,andloading
acceptablejackextensions
adequatebracingtoensurestability.
Pre-pourinspectionsarethelastreasonableopportunitytoensure
compliancewiththeformworkdesignspecications.Suchinspection
records form an important part of the site quality control system and
mustbesigned-offbyanengineer,formworkdesignerorcompetent
personfollowingthenalpre-pourinspection.Asamplepre-pour
structuralinspectioncerticateisprovidedatAppendix5.
c dt i w yt
Appendix6illustratessomeofthemorecommondefectsthat
are likely to occur in a formwork system. The list is intended to
8/22/2019 Formwork Guide
10/379
give guidance to a competent person and is not considered to be
exhaustive.Inanyindividualcase,theimportanceofitemsmayvary
and only a competent person can assess their relative importance.
3. cdiati ad adiitati
3.1 Work ProgrAm
Therisktoapersonshealthandsafetymustbeconsideredwhen
designingaworkprogramforerecting,alteringordismantling
formwork.Considerationshouldbegivento:
edgeprotectionrequirementsandensuringthesearedesigned
and constructed in a timely manner to be safe to use
sequencingworktoensurethatsufcienttimeandresources
are allowed for each work activity
coordinatingtradestoallowworktobecompletedfreefrom
obstruction.
3.2 HousekeePIng Access AnD sTorAge
Formworkconstructionresultsinaconstantlychangingwork
environment,withrestrictedaccessthroughframesandformwork
supports,oftenwithlargevolumesofmaterialandwaste.Forthis
reason,itrequiresongoingmonitoringofhousekeepingpracticesto
maintain a safe and productive workplace.
Include housekeeping as an essential aspect of every job whether
itbethroughworkinstructions,regularinspectionoftheworkplace,or site/task induction training. Instructions should include time and
resources for the progressive clean up of work areas to prevent
rubbishandredundantmaterialsfrombecomingatriphazardandto
allow safe access for mechanical aids.
3.2.1 A ad
TheOHSWRegulationsrequirethattherebeclearaccessto
andfromtheworkplaceinaccordancewithDivision1Access
and egress.
Clearaccessisimportantforthesafemovementofmaterials,
equipment and anyone on-site. Designated access ways should be
providedandanyoneon-siteshouldbedirectedtousethem.Access
waysmustbekeptclearofanyrubbish,plantormaterials.
Insomesituations,greenhazardtaping/buntingorothervisual
methods can clearly show where access ways are located. This
is particularly important where access is required through
formwork frames.
Emergencyaccessandegressmustbeprovidedtoallpartsofthe
workplace. The following situations should be considered:
stretcheraccessandegress
peoplecarryingtoolsandequipment
useofstairs
provisionoftwomeansofegressatalltimes.
3.2.2 matia ta
TheOHSWRegulationsrequiresafestackingandstorageofplant
andmaterialsataworkplace,asdetailedinDivision15Storage.
Materialsmustbestoredinawaythatminimisesmanualtask
hazards,triphazardsandthepotentialforhazardsfromfallingobjects.SmallercomponentssuchasU-heads,couplers,baseplates
andZ-barsshouldbestoredinlabelledmaterialboxes,markedwith
safeloadlimits(SLL).
Wherepracticable,frames,formplysheets,bearersandjoists
should be strapped in bundles or stacks and be located away from
theedgeofthedeck,topreventmaterialsoranyoneaccessingthem
from falling.
Wallformsshouldbestackedinsuchawaythattheycannotslide,
orrotateawayfromthesurfacetheyareplacedagainst.Anengineer
shouldverify,inwriting,thatasurfacetobeusedforstackingforms
iscapableofwithstandingtheimpactofallimposedloads,including
windloading.Ifpurpose-madeA-framesarenotavailablefor
storingwallformswhennotinuse,itispreferabletolaythemat
ontheground,ratherthanleaningthemagainstotherstructures.
Timbers,orothereffectivemeansofsupport,shouldbeusedunder
forms where slings are to be used for lifting.
3.2.3 rih ta ad a
Rubbishstorageandremovalforformworkmayincludethe
provision of rubbish skips and wheelbarrows that are moved as work
progresses.However,rubbishskipsmayonlybepositionedwhere
the supporting structure has adequate strength to support the total
weight of the bin and its likely contents.
3.2.4 sta t iii aa ta i
Incorrect material delivery and storage practices can create
signicantmanualhandlingrisks.Safeworkpracticesthatcanassist
in minimising these risks include:
ensuringthatformworkmaterialsaredeliveredascloseas
practicable to the job
designinganddesignatingasmallsectionoftheformworkdeck
as a loading platform for ply and other components
ensuringmechanicalaidsareusedtohandleloadswherever
possible
storingloadsontrolleystominimisedoublehandling,oron
raised platforms to minimise manual lifting from ground level
havinganadequatestoragespaceorlaydownareastosafely
store materials/equipment and to minimise double handling.
8/22/2019 Formwork Guide
11/3710
3.3 TrAInIng
Anyonewhomaybeexposedtoworkplacehealthandsafety
risks resulting from formwork construction must be provided with
informationandtrainingthatisspecictotheformworksystemthat
is being used. Training and information should include details of:
theformworksystem,components,tasksandactivities
thewaythemanufacturerordesigneroftheformworksystem
intendedittobeerected,installed,used,moved,alteredor
dismantled
therangeofhazardsassociatedwiththeformworksystem,
controlmeasurestominimiseexposuretotherisks,thecorrect
use of controls and how to ensure controls are maintained
anyspecialrequirementstoundertakeorparticipateinspecic
tasks or activities
anysafeworkmethodstatements,includingtheuseofmechanical aids and devices
theuseandmaintenanceofequipment,includinganyspecic
conditionsandprohibitionsonitsuse.Wherenecessary,
referenceshouldbemadetooperatorsmanuals
anyspecialsafetyinformationneeded,suchassafety
precautions for working under certain conditions including hot
workorconnedspacework
personalprotectiveequipmentrequirements,including
instructionsfortting,use,cleaning,maintenanceandstorage
theavailabilityandcontentofthisindustryguidancedocument.
FortrainingdetailsrefertoAppendix2.
4. W t
4.1 formWork erecTIon TrADITIonAl sysTems
TheOHSWRegulationsdescribewhatmustbedonewherethere
isariskapersoncouldfallinDivision13PreventionofFalls.
Thelegislationalsorequiresthatahazardidenticationandrisk
assessmentbeconductedand,wherenecessary,safeworkmethod
statements documented.
Formworkactivitiesmustcomplywithregulatoryrequirements
fortheerectionofscaffolding.Formwork,likescaffolding,mustbe
erectedsafelyandsystematically,andbetiedinprogressivelyto
stabilise the structure.
Apersonmustbeprovidedwithaworkingplatformatleast
450mmwide(i.e.twoplanks)evenwhenthepotentialfalldistance
is less than 2 m. It is not acceptable for a person to work from a
single plank or bearer.
Irrespectiveofwhichframingsystemisused,workersmustalways
use working platforms that are two planks wide as a minimum.
Whereapersonistoinstalljoists,thiscanbeachievedusingatwo-
plankworkplatformfromunderneath,allowingtheverticaldistance
between the formwork deck and the false deck to be increased. This
isillustratedinFigure3below.
Figure 3 Worker erecting ormwork on two planks
>2.0
vArIAble
8/22/2019 Formwork Guide
12/3711
4.1.1 fdati
Formworkmustbeerectedonastablebasetopreventtherisk
ofcollapse.Suspendedslabsmustbeabletosafelysupportloads
thatmaybeappliedbytheconcretepour,workersandcrane-lifted
loads etc.
Baseplatesmustbeprovidedunderpropsandstandardson
formworkframesunlesstheproporstandardhasanintegralfoot,or
an engineer documents that a base plate is unnecessary.
Soleboardsdesignedtosuitthegroundconditionsmustalsobe
usedunderpropsandstandardsonnaturalground,unlessan
engineerstatesotherwise.Framesandpropsmustbelocatedon
asoundbasethatwillnotsubside,failorwashaway.Theprincipal
contractor is responsible for providing all information on ground
conditions to the engineer or formwork designer.
4.1.2 fa d
In situations where a deck is being installed at a height that would
require a person to stand at a height of 2 m or more to install bearers
andjoists,acontinuousfalsedeckshouldbeprovided(seeFigure
4below).Thisisafulldeckthatisthesameareaastheoorbeing
formedbutupto2mbelowthetruedeck.Asindicatedinsection4.1
above,thedistancebetweenthefalsedeckandthetruedeckcanbe
increasedwhereaworkplatformisused.However,thefalldistance
from the work platform to the false deck must not exceed 2 m.
The false deck should be continuous both inside and between
formworkframesandtypicallyconsistsofformply,scaffoldplanksor
modularplatformsections.Aprotectedaccessopeningcanbeleftin
the deck for lifting in materials.
The use of a captive platform is preferable to lapped planks
because a captive system cannot be accidentally dislodged and its
constructionalsominimisestriphazards.Lappedplanksmayonly
be used if they are secured against uplift and slippage. The false
deckshouldbeconstructedsuchthatnogapexceeds225mmin
width and gaps only exist where a vertical member of a frame passes
through the deck.
The false deck should be designed to have adequate strength to
support:
anyonerequiredtostandonthedeck
materialsthatneedtobeonthedeck
anymaterialsorworkersthatshouldhappentofall.
The deck must be able to withstand:
apointloadof2kNdistributedoveranareaof100x100mm
(2kNisapproximatelyequivalenttoamassof200kg)
auniformlydistributedloadof2kPa,whichisequivalenttoa
mass of 200 kg per m2.
Whenconsideringthedesignofthedeckforerecting,alteringor
dismantlingformwork,theweightofthefalsedeckandanyadditional
live loads must be applied to the analysis of the formwork support
structure.
The height between the false deck and the pouring deck should allow
comfortable access for a person during stripping.
4.1.3 eti a
Anyoneinvolvedinerectingformworkframesmustbetrainedto
dothissafely.Apersonsupervisingtheerectionofformworkframe
systemsmustbeacompetentperson(asdenedinAppendix1).
TheOHSWRegulationsprovidetherequirementsfortrainingand
responsibilities of workers performing a class of high risk work.
In cases where scaffold equipment is used as a formwork support
structureanditispossibleforapersonorobjecttofall4mormore
fromthescaffold,theOHSWRegulationsrequireapersontohold:
aBasicScaffoldinglicence(SB)toerectproprietaryframes
or
anIntermediateScaffoldinglicence(SI)toerecttubeand
ttingscaffold.
Traineesarepermittedtoperformscaffoldwork,providedtheyare
under the direct supervision of a competent person who holds the
scaffolding licence necessary for the task.
Formworkframesshouldbeerectedinaprogressivemannerto
ensureboththeinstallerssafetyandthestabilityoftheoverall
structure.Bracingistobeattachedtotheframesassoonas
practicable. The risk of a fall from edges of formwork frames during
theirerectionishigh.Inthissituation,itisnecessarytoinstalledge
protection on the frames as they are erected.
Conventionalformworkframesincludediagonallyhingedbracesthat
crossinthemiddle.Whilethesebracesarenotconsideredtobe
suitableedgeprotectionforacompletedformworkdeck,basedona
riskassessment,theymayprovidereasonablefallprotectionduring
frameerection.Suchfallprotectionexistsonlywhenbracesare
installedimmediately,andinaprogressivemanner.
Figure 4 A alse deck
Gap not to exceed 225 mm
8/22/2019 Formwork Guide
13/3712
Astheheightofformworkframesincreases,thereisagreaterneed
toprovidelateralstabilitytotheframestructure.Allframingmustbe
carried out so that it complies with on-site design documentation and
anymanufacturersrequirements.
4.1.4 Itai a
Whenpositioningbearers,installersmustbelocatednomorethan
2mfromtheoororthefallarrestingplatformlocatedimmediately
belowthem.Forexample,bearerscanbeliftedontothetopofthe
formwork frame by a person standing on a work platform erected
withintheframeandnomorethan2mfromtheoororfalsedeck
locatedimmediatelybelow(seeFigure5below).
Bearersmustbepositionedsuchthattheywillnotfallfromthe
frames. The common methods of ensuring this are to place the
bearersinU-headsontopoftheframesandalsobyensuring
cantileversareminimised.WhereonlysinglebearersareplacedintheU-head,thebearermustbeplacedandxedcentrallyinthe
U-headunlessaformworkdesignerorengineerstatesotherwise.
4.1.5 Itai it
Whereafalsedeckisprovidedat2morlessbelowformworklevel,
joists may be spread on the bearers with the worker standing on the
false deck. If the height of the formwork deck being constructed is
morethan2maboveacontinuousdeckorsurface,joistsmustbe
spreadfromaworkplatform,atleasttwoplankswide,andlocated
within 2 m of the surface underneath the deck being constructed(refertoFigure5).
Oneexampleofaworksystemthatmaybeusedtodothisis
as follows:
The joists are lited by the workers and spread on top o the
bearers into their approximate fnal positions whilst standing on a
lower work platorm. The platorm below the deck must be
positioned at a comortable height or handling joists (without
introducing manual task risks) and not greater than
2 m rom the alse deck.
4.1.6 fa ptti th w d
Continualmodicationoffallprotectionmeasuresisnecessary
during formwork construction because the structure is constantly
changing.Oneofthebiggestchallengesistoprovideadequatefall
protection on the leading edge of the formwork deck.
Wherethereisonlyoneleadingedge(i.e.theotheredgesareprovidedwithscaffoldingedgeprotection),theprovisionoffall
protectionisrelativelystraightforward.However,wherethereare
multiple leading edges and/or the deck is not at one consistent
level,theprovisionoffallprotectioncanbedifculttoimplement.
Designersofbuildingsarethereforeencouragedtodesignoorslabs
thatareoneconsistentthickness(refertosection2.1.1Buildability).
Leadingedgeandperimeterprotectionmustbeprovidedonedges
where the potential fall distance is 2 m or more and a person is not
preventedfrombeingwithin1.8moftheedge.Controlmeasuresare
requiredwhereapersoncouldfall,fromanyheight,ontoanobject
suchasframes,reinforcingsteelorarubbishskip.
Figure 5 Setting U-heads, bearers and joists
rom a two-plank platorm
2.0
8/22/2019 Formwork Guide
14/3713
4.1.7 ed ptti th w d
4.1.7.1 fw tti z phia ai
Aphysicalbarriershouldbeprovidedandmaintainedtoseparatethe
formworkworkzonefromotherworkers.Thisbarriermustberigid,
capable of maintaining its integrity in an upright position and capable
ofsupportingsignageifrequired(seeFigures6aand6babove).
The use o ags and tape or unsupported barriers is not
acceptable.
Wherethedesignoftheformworkiscomplexandtheproleof
thedeckisconstantlychanging,constructionofleadingedge
protectionmaycreatemorehazardsthanitwouldcontrol.Insuch
cases,itmaybeimpracticaltoprovideedgeprotection,asanyone
installing the edge protection would be exposed to the risk of falls.
In some situations perimeter edge protection must be installed.
Examplesinclude:
wherethereisachangeindeckheightalongthesideofthedeck
beingconstructed,(i.e.adropdownforabeam)andnojoistsor
form ply have yet been installed at this different height
wherealeadingedgeistobeleftunattendedandaccessonto
thedeckisrequiredbyanyoneotherthanformworkers(i.e.the
formwork deck has not been barricaded off and marked with
keepoutsigns).
4.1.7.2 ed ptti ptd d
The most effective means of providing edge protection on a
completed formwork deck is to install perimeter scaffolding.
Scaffoldingiserectedpriortotheformworkand,therefore,prevents workers falling from the completed deck. The advantages
ofthissystemarethatedgeprotectionforinstallersofthenal
perimeterformplysheetsisalreadyinplace,thereisnorequirement
toinstalledgeprotectionontheperimeter,andnoexposuretoarisk
of falling.
Insomeraresituations,itmaybeimpracticaltoprovideperimeter
scaffolding.Insuchcases,edgeprotectionmustbeinstalledandthe
work system used for this installation must include a control measure
against the risk of a fall.
Theuseofharnesssystemsisdiscouraged,becauseitdoes
not provide an adequate level of protection from injury and is an
impractical control for the risk of a fall from height in formwork
erection(refertosection1.1ofthisguide).
Insomesituations,edgeprotectioncanbesubstitutedwithan
alternativemeasure,providedthismeasurepreventsapersonfalling
fromtheedge.Onealternativeistheprovisionofabarricade,1.8m
fromtheedgewithclearlyvisiblekeepoutsigns.
Furtherguidanceonstanchions,guardrails(handrails)andmid
railsforminimumstrengthandrigidityisspeciedinAS 1657 Fixed
platorms, walkways, stairways and ladders Design, construction
and installation.
Wherescaffoldingisover4minheight,onlylicensedandauthorised
scaffoldersmayerect,dismantleoralterthescaffolding.Anyscaffolding components that are temporarily removed must be
replacedattheearliestopportunity.Anygapsbetweenacompleted
oorandscaffolding,thatmayexistaftertheformworksupport
systemisremoved,mustbecoveredwherethereisariskofa
person or materials falling through.
4.1.8 lai a w d
4.1.8.1 gtti tatd a a
Afterthesupportingframes,bearersandjoistsareinposition,the
rstessentialconsiderationinlayingaformworkdeckisthatall
building work conducted at height requires some type of perimeter
protection.Thesecondessentialconsiderationisthat,forfall
prevention,workersmuststayawayfromaleadingedge.Howthese
essential elements are achieved is determined by the builder.
Figure 6a General view Figure 6b Fixing detail
Acceptable solid work zone barrier with No-Go zone below
8/22/2019 Formwork Guide
15/3714
Therststepinlayingoutaformworkdeckistoprovidesafeaccess
andaheavydutybaytoloadandstorematerials,particularlyapack
offormply,attheformheight.Successfulsolutionswillbepartially
guidedbythesiteitself,thesizeofthejoborthecontractors
preferredsystem,andmaybeanengineeredsolution,ascaffold
solutionoraformworksupportsystemsolution.Eachhasadvantagesand disadvantages.
eid ti
Generally,engineeredsolutionsareeconomicaltoassemble,
disassemble,useandmaintain,andmaybedesignedforahigher
load-carryingcapacity(withsufcientsupportframecapacity).They
are more suitable for larger projects with more site room.
Engineereddeckunitsarepositionedandliftedbymechanical
aids,suchasmulti-purposetoolcarrier,forkliftorcrane,thus
reducing the risk of injury from manual tasks. Drop-in hand railing
systemsareeasilyinstalledatgroundlevel,reducingtheriskoffalls
during erection.
However,engineeredsolutionsgenerallyhaveahighercapitalcost
todevelop,manufactureorpurchase.Engineeredsolutionsareless
exiblebecausetheremustbeaclearaccesswayof450mm.This
limitsavailablespaceforstorageofmaterialsonthedeck(seeFigure
7below).
sad ti
Scaffoldsolutionsmaybemoreexibleintheirarrangementand
would normally require a lower initial capital investment than
engineered solutions. They are generally more suitable for smaller
jobsandrestrictedsites.Scaffoldsystemloadingbaysaremanually
erected,withtheplatformareaandhandrailsbeinginstalledat
height,increasingtheriskoffallsduringerection.
The load carrying capacity of scaffold-based systems is generally
lowerthanengineeredsolutions,beingheldwithintheallowable
limits forAS/NZS 1576.1:2010 Scaolding Part 1: General
Requirements.However,scaffoldingmaybespecicallydesigned
forhigherloads.Workplatformsdesignedforhigherloadsmust
prominentlydisplayasignindicatingtheSLL.
Scaffold-basedsystemsaregenerallymoreadaptableinallowing
forincreasedsizeofstoreditems,notnecessarilybeinglimitedtothesizerequirementsof2400x1800mmformplysheets,whilst
maintainingthenecessary600mmminimumaccesswidth.
fw ppt t ti
Packsofformplysheetsmaybeplaceddirectlyonthejoistsofa
formworksupportsystemundercertaincircumstances.Asection
of the formwork support system may be a nominated loading area
providing:
thenominatedloadingareaiscertiedbytheengineeror
formwork designer
themaximumSLLoftheareaismarkedontheformwork
drawings,togetherwithadditionalproppingrequirements
Figure 7 Engineered loading bay.
Note: Drop-in handrails in place, liting eyes, orklit slots, and built-in bearers
8/22/2019 Formwork Guide
16/3715
anynecessaryadditionalpropsareinstalledandinspectedprior
to loading
aperimeterscaffoldisinplaceforfallprotection
theloadingareaissafelyaccessiblefromaperimeterscaffoldor
other safe access structure
alljoistsandbearersformingpartoftheloadingareaare adequatelysecuredinpositiontopreventafall,asdescribedin
section4.1.8.3ofthisguide
layingtheformplydeckproceedsasdescribedinsection
4.1.8.3ofthisguide
astartingpointforlayingthedeckisclosetotheformply
stack so as to minimise worker exposure to the risks of injury
from manually handling the form ply sheets.
4.1.8.2 Tpia w t a adi d
The following work system may be used to construct the formworkdeck for typical multi-level construction. The work system is
specicallyintendedforsituationswheretheverticaldistance
belowthedeckbeingconstructedisgreaterthan2m,butwiththe
use of false decks may be used irrespective of the distance to the
oorbelow.
1. PlacebearersontheU-headsoftheformworkframesfromthe
workingplatformprovidedimmediatelybelow.Securebearers
topreventmovement,i.e.bynailingto,orwedgingin,the
U-headsbeforejoistsareplacedontop.Noeccentric(un-
centred)loadsshouldbeappliedtotheU-headsunless
specicallyallowedbytheformworkdesigner.
2. Placejoistsonthebearersinaprogressivemannerfromthe
work platform located directly below the area to be worked
on,andspacedat450mmcentres(maximum)orsothatthegap
betweenjoistsdoesnotexceed400mm.Securethejoists
against any movement should a worker fall onto them.
3. Secureanycantileveredbearersandjoiststopreventupliftor
dislodgement prior to anyone working on them.
4. Layoutformply,orotherdeckmaterial,progressivelyas
describedinsection4.1.8.3.Whereverpossible,thedirectionof
theleadingedgeshouldbeperpendiculartothejoists,i.e.
paralleltothebearers(referFigure8).
Formplyshouldbeplacedonthejoistswiththeinstaller
located behind the sheet as it is positioned whilst standing on
the previously laid sheet or work platform provided. If this is
doneconsistently,shouldapersontriporstumbletheywould
fall onto the sheet and not from the leading edge.
Planningshouldtakeintoaccounttheoptimumpositionfor
theloadingbay,ordirectionofformplyplacementsothatlaying out of the sheets starts at the loading bay where the
formplyisinitiallystacked,reducingtheneedformanual
handling and carrying sheets.
5. Coverorprotectallpenetrationsleftbehindtheleadingedge.
Coversmustbesecurelyxedandclearlysignedtoindicatethey
areprotectingapenetration(seesection4.1.10).
6. Nailorotherwisesecureformplytothejoistsassoonas
practicable.
Iftimbershavenotbeenxed,edgeprotectioncomplying
withOHSWRegulations2010(Division13Preventionof
Falls),mustbeerectedleadingawayfromthesidesofthe
leading edge.
Onlypersonnelinvolvedintheconstructionoftheformwork
maybelocatedintheformworkconstructionzone.Anyone
not involved in this process should be excluded.
Theleadingedgemustbefreeofoil,sawdustand
obstructions to reduce the likelihood of slips and trips.
4.1.8.3 lai a p d
Aformworkdeckmustbelaidinaprogressivewaythatincludesa
method of preventing falls below the deck. This control measure is
particularly important in situations where a false deck has not been
providedwithin2mbelowthelevelofthedecktobelaid,andthe
potential fall distance is therefore greater than 2 m.
Whereafalsedeckhasnotbeenprovidedwithin2m,formplymay
only be spread on the joists where:
aminimumoffourjoistsat450mmcentres(400mmgaps,
totalling1.8m)arelocatedonbearersnexttotheperson,
andthejoistsextendforatleast1.8mallround(seeFigure8).
Therefore,intheeventofafall,thepersonwillfallontothejoists
and be prevented from falling further
layingtheformplysheetscommencesfromtheperimeter
scaffolding or other edge protection that has been provided at
theperimeteroftheformwork,e.g.attheloadingbaywheretheform ply is stacked
theformplyislaidinfrontofthebodysothatifthereisa
stumble,thefallislikelytobeontopofthesheetsbeinglaid
Figure 8 Maximum spacing o timbers around worker
where alse deck is over 2 m below
400 mm
1.8 m
1.8 m
8/22/2019 Formwork Guide
17/3716
joistsarexedtopreventsidewaysmovement.Insome
situations,theremaybeapossibilityofapersonfallingthrough
thejoistsifthejoistsspreadasthepersonsbodymakescontact
with them during a fall. This is more likely to be a potential
hazardwhenthepersonsfallisinthesamedirectionasthe
layofthejoists.Fixingjoiststopreventsidewaysmovementwillminimise this possibility.
4.1.8.4 lai a ta d
Ametaldeckshouldbelaidinaprogressiveway.Whereafalsedeck
has not been provided within 2 m below the level of the deck to be
laid,metaldecksmayonlybelaidwheretheuseoffallprevention
systemshavebeenprovided.Worksystemsfollowingthehierarchy
ofcontrolsmustbeused.Examplesincludeelevatingworkplatforms,
scaffolding,personalfallprotectionsystemsandanti-glaremeasures
(refertoFigure9).
4.1.9 cati qit
AS/NZS 4576: 1995 Guidelines or Scaoldingrequires that
the design of cantilevered scaffolds and the adequacies of their
supportingstructuresmustbeveriedforcompliancewiththe
relevant requirements ofAS/NZS 1576.1 Scaolding Part 1: General
Requirementsbyacompetentperson,suchasanengineerwith
experience in structural design.
Cantileveredbearers,joistsandplysheetscanbehazardouswhen
left unsecured. The weight of a person standing on the cantilevermaycausetilting,resultinginthepersonormaterialfalling.
Formworksystemdesignersshouldminimisetheuseofcantilevers
wherepossible.However,insomesituationswherecantilevered
sectionsareunavoidable,theformworkdesignerorengineer
must consider the potential for people and stored materials to
causecantileverstopivot.Formworkdesignsmustindicatewhere
cantilevers are to be positively secured so that the weight of a person
or material does not cause the section to pivot.
4.1.10 Ptati
Anypenetrationwherethereisariskthatapersonoranobjectcould
fallthroughmustbecoveredorsecurelyguarded.Openpenetrations,
suchasstairwellvoidsorpenetrationstoallowforservices,create
hazardsforanyoneonaformworkdeck.Apersonmayfallthrough
largerpenetrations,sustaininjurybysteppingintoasmallerpenetration,
oranobjectmayfallthroughtheopeningontoworkersbelow.All
penetrations must include cast-in metal mesh as a backup system.
Themeshshouldhaveasmallaperture(e.g.50x50mmmeshsize
orsmaller),andbemadeofmaterialcapableofwithstandingthepotentialimposedload.Meshprovidedoverlargepenetrationsmay
requireengineeringcerticationtoensureitcanwithstandpotential
loadsincludingpeople,equipmentandmaterials.
Whereholesarecutinthemeshforservicestopassthrough,the
holeshouldbecuttotheproleoftheservicesothatmeshremains
covering the penetration.
Ungradedplywoodcoversarenotadequatebecause:
thecovermaybeindistinguishablefromotherpiecesofply
itmaybedifculttodetermineiftheplywoodisproperlysecured securedplywoodcoverscanbeunsecuredtogainaccessand
subsequently may not be re-secured.
Figure 9 Sae Work System or laying metal deck
(Note:Fallpreventionsystems)
8/22/2019 Formwork Guide
18/3717
Plywoodcoversmustbe:
structurallygradedandsound
aminimumof17mmthick
paintedabrightcolour
non-slip
markedwiththewordsDAnger PeneTrATIon beloW.
Thecovershouldbermlysecuredtotheconcreteanddesigned
forpotentialloadsthatmaybeapplied.RefertoFigure10foran
acceptablepenetrationprotectiondesign.Beforestrippingformwork,
ensure the penetration that will be exposed is securely covered and
protected.
Penetrationsarealsohazardousbeforethedeckislaid.Joists
placed up to the edge of the penetration must be secured so that the
timbers cannot spread if a person falls on them.
4.1.11 Wi z w ad th
Theformworkconstructionzonemustbesufcientlylargetoensure
that formwork areas are clearly separated from other work areas.
Aformworkconstructiononlyzonemustbemaintainedbehind
theleadingedge.Thiszonemustbeclearlydemarcatedbysignageandameshbarrier.Figure11illustratestheotherworkzone,the
formworkzoneandthearearetainedasedgeprotection(fourjoists
spaced1800mmbeyondthelaiddeck).
Figure 10 Example o acceptable penetration protection
*Reer to 4.1.7.1 Formwork construction zone physical barriers
Figure 11 End view o deck showing working zones
100 mm
(min)
100 mm
(min)
DAngerPeneTrATIon
beloWSLL where required
Zone for
oTHer
Workers
formWork
consTrucTIon
Zone
This distance may vary
depending on work
requirements
Physicalbarrier*
Dynabolt,orsimilar
anchorage
exap i
Min17mmthick 50mmmeshcastincentrally
FloorslabFloorslab
8/22/2019 Formwork Guide
19/3718
4.1.12 Changingoorlevels
Formworkdecksmaynotbeatacrosstheentireoor,dueto
deepbeamsordropdowns(sometimescalledcapitals)around
columns.Suchvariable,unevenoorsintroducetripandfallhazards
duringformworkerection.Itispreferablethatthesehazardsare
eliminatedatthedesignstage(seesection2.1.1Buildability).
Fallandtriphazardssuchasthesearemosteffectivelymanaged
by ensuring that lower level formwork supports and decks are
progressively constructed before work commences on the higher-
level areas of the deck.
4.2 formWork erecTIon moDulAr
formWork sysTems
4.2.1 bai da t
Thebasicprinciplesdiscussedinsection4.1ofthisguideontraditional systems apply to the erection of modular formwork
systems.Althoughtheerectiontechniqueandmemberdimensions
mayvarygreatlybetweentraditionalsystemsandmodularsystems,
the principles of maximum potential fall distance and gap width at
the working level are applicable:
thewidthofanygaponaworkinglevelisnottoexceed
400mmunlessafalsedeckhasbeenprovidedwithin2m
of the working level
workingplatformsusedformodularsystemsmustalsohave
aminimumwidthof450mm.Bothmodularandtraditionalformworksystemsmustbedesigned
to comply with the loadings and general principles ofAS 3610:
Formwork or Concrete.
Traditional formwork systems are sometimes used adjacent and
connectedtomodularsystems,particularlyforunusuallyshaped
areas.Wherethisisthecase,theformworkdrawingsshouldshow
anyessentialconnectionordesigndetailsandbecertiedbyan
engineerorformworkdesigner.However,componentsfromone
proprietary type of formwork system should not be used as integral
parts of other modular formwork systems unless the designer of themodular system states in writing that this is permitted.
Modularformworksystemsareoftenmanufacturedfromaluminium
insteadofsteelandarethereforelighterinweight.Beinglightweight,
theyrequirelessphysicalefforttoerectthantraditionalsystems,and
alsotheneedforrepetitivehammeringmaybeeliminated,reducing
workersexposuretotheriskofinjuryfrommanualtasks.
Becausemodularsystemsarelighterinweighttheymaybemore
susceptible to overturning during erection when exposed to eccentric
loading factors such as wind loading etc. This is generally an issue
only prior to placement of the decking on the modular support
system.Toeffectivelycontrolanyinstability,modularformwork
systems must be progressively braced during erection in accordance
withthemanufacturersinstructions.
4.2.2 Taii
Workersinvolvedintheerectionofmodularformworksystemsmust
be trained in the safe erection and dismantling of the system and the
inspectioncriteriaforcomponents,particularlyfordefectsthatwould
preclude their use.
The modular system supplier or designer should provide written
instructions for the erection and dismantling of the system.
Instructions should include safety instructions equivalent to those
detailed in this guide.
Trainingbythemodularformworksystemsupplierisencouraged.For
trainingrequirementsrefertoAppendix2.
4.3 sTrIPPIng formWork
Strippingformworkcanbeoneofthemosthazardousphasesof
concrete construction.
Whilefallingobjectsaretheprimaryhazard,theremayalsobefall
hazardsasaresultofoor,scaffoldorformworkcollapse,aswellas
manualtaskhazardsfromapersonworkinginawkwardpostures,
repetitivehandlingofmaterials,orlimitedtaskvariety.
Workersmustbeinformedoftherisksandbeadequatelytrained,
sothatstrippingoperationsarecarriedoutinanorderly,progressive
manner,asoccurswithformworkerection.
4.3.1 ga w tippi
To reduce the risk of injury when stripping formwork/false work:
installfully-deckedworkplatformsataheightnogreater
than 2 m from ground level or the catch deck
erectacatchdecknomorethan2mbelowtheworkarea
suitablybarricadeandsignpostthestrippingarea
(withbarriermeshasaminimum).
4.3.2 sa w thd tatt
Onlyanexperiencedandcompetentpersonshouldpreparesafe
workmethodstatementsforthestrippingoperation.Properly
prepared statements are very useful as a training tool for those
who will be involved in this high risk activity. The safe work method
statement should detail factors such as:
thehazardsrelatedtothestrippingprocessandanyequipment
and strategies to eliminate or minimise the risks
thenumberofpeopleinthestrippingcrew
thesequenceofstrippingactivitiese.g.detailinghowtheframes
and/orothersupportsaretoberemovedandhowfarU-heads
may be lowered
whetherthesupportsystemmaybecompletelyremovedina
zonepriortoremovaloftheformworkdeck,orwhetherthe
supports are to be lowered slightly but still remain under the form
ply while it is being removed
8/22/2019 Formwork Guide
20/3719
whenback-proppingisrequiredoronlypartofthesupport
systemistoberemoved,howthestructuralmembersareto
remain in place and/or the type and layout of members that will
replace the formwork system
anyotherspecialrequirementsinvolvedinthestrippingand
or building processes e.g. checking of back-propping afterpost-tensioning.
4.3.3 Certicationpriortostripping
Priortocommencementofthestrippingoperation,anengineermust
providewrittencerticationthatformworkcanberemoved.This
certicationshouldbebasedonanengineersspecicationsforthe
building,thestrengthoftheconcretemixandthetimeperiodthat
has elapsed since the pour.
Anengineermayalsoberequiredtohaveinputintothestripping
safe work method statement to ensure the concrete element
doesnotfail,andmustprovidesufcientdetailonthestructural
engineeringdrawingsasrequiredbysection17Formworkof
AS 3600 Concrete Structures.
Documentation from the concrete supplier verifying the concrete
specicationshouldbeavailableonrequest.Aconcretesampling
and testing procedure should be in place to verify that concrete
meetsitsdesignspecicationforstrippingpurposes.Guidance
on sampling and testing systems for concrete is provided in
AS 1379:2007 Specifcation and Supply o Concrete.
4.3.4 exi z
Onlythoseinvolvedinthestrippingoperationarepermittedinan
areatobestripped.Strippingareasmustbecordonedoffand
signs displayed to keep non-essential personnel out of the area
e.g. DAnger formWork sTrIPPIng In Progress
AuTHorIseD Persons only.
Itispreferabletorestrictaccesstothewholeoorwheresoft
strippingistakingplace.Thiswouldnotonlybesafer,butalso
reduces the quantity of signage and barricades required.
Whereothertradesorsub-contractorsarerequiredtoworkonthe
sameoorduringthestrippingofwalls,columnsorsmallsectionsof
soft,theprincipalcontractororemployermustensurethatcontrols
are applied to prevent non-essential personnel from entering the
stripping area.
4.3.5 Dp tippi
Drop stripping is an unsafe method of work and cannot be supported
by this guidance document. In cases where drop stripping is being
considered,theformworkandsupportdesign,andtheconcreteelementdesign,shouldbereviewedbythedesignerandmodiedto
eliminate drop stripping.
4.3.6 bd dti
Strippingofformworkmaybeaidedbyreducingthebondbetween
theformmaterialandtheconcrete.Bondstrengthisdependenton
thematerialcharacteristics,thesmoothnessoftheformmaterial
and age of the concrete. The use of a liquid bond breaker on wall
and column forms is one way of reducing the strength of the bond.
However,theuseofbondbreakeronoorformsisnotencouraged
becauseofthesliphazardthatmayresult.
4.4 crAne AnD oTHer loAD HAnDlIng sysTems
4.4.1 ladi atia di w tti
Formworkstructuresarenotnecessarilysafetoacceptanyexcess
loadinguntiltheyarefully-secured.Thatis,untilafterthedeckisin
placewithtie-insandproppingcomplete,andanyproposedloading
areacertied.
Inpractice,someloadingoccursbeforeadeckiscompleted
e.g. unloading pallets of ply and joists on a partially constructed
formworkstructure,tocontinuethedeck.Thisisanunacceptable
and dangerous practice which could lead to a full structural collapse
ofthedeck,possiblyresultinginseriousorfatalinjury.Toensurethe
integralsafetyofthedeck,materialsmayonlybestoredwhereand
whenthedeckiscertiedasabletobeartheload.
Formworkersandcranecrewsmustbemadeawareofthespecic
locationsandloadsforcertiedloadingareas,andthatstacked
materialsmaycreatepointloadings,whichaformworkstructuremaynot be designed to bear at that point.
Tominimisetheriskofcollapseandotherhazards:
loadsmustnotbeplacedontheformworkdeckifthe
formwork documentation prohibits loading
formworkdrawingsmustclearlyidentifythelocationsand
SLLformaximum(pre-pour)pointloadingsforthedeck.These
locationsmustbespeciedbyaformworkdesignerorengineer
cranecrewsmaynotliftmaterialsontothedeckuntilthereisa
designatedliftingzone
cranecrewsmustbenotiedwhenanareaofdeckisreadyto
takeaload,andspeciedloadsmayonlybeplacedinthearea/s
designated and placed so that they cannot fall
deliveryofmaterialstothesiteshouldbeplannedsothatloads
are not lifted onto unsecured decks
priortoworkersleavingthesite,materialsandequipmentshould
be secured to prevent them being moved by wind.
4.4.2 sii ad
Slingingandun-slingingloadsatheightisalwaysahighriskactivity.
Safeworkmethodsandfallpreventionsystemsareessentialforthis
activity(refertosection4.1.8.1)
Adogman,orotherpersonengagedinslingingloads,mustbe
provided with adequate fall protection and a safe means of access
8/22/2019 Formwork Guide
21/3720
when working at 2 m or more above the deck.
The use of fall arrest systems for workers slinging formwork
loadsisusuallyimpracticalandisnotrecommended.However,it
maybereasonablypracticabletotplatformsandedgeprotection
as fall protection.
4.4.3 liti a
Guidanceontheuseandinspectionofchains,wireropesand
synthetic slings is provided in the following publications:
AS 2759: 2004 Steel wire rope Use, operation and
maintenance
AS 3775.2: 2004 Chain slings Grade T Part 2: Care and use
AS 1353.2: 1997 Flat synthetic webbing slings Part 2: Care
and use.
Basicitemsthatneedtobecheckedinclude:
liftinggearistaggedandallrelevantinformationlisted
(e.g.relevantinformationforachainslingisgradeofchain,
safeworkingload,manufacturer,chainsizeandAustralian
Standardmarking)
liftinghookshaveoperablesafetylatches
liftingeyesandinsertsarecompatible
liftingslingsareserviceableandnotdamaged(i.e.haveno
excessivewear,damagedstrands,cracks,deformationand/or
severecorrosion)
syntheticbreslingsaremaintainedingoodcondition,arerated fortheloadbeinglifted,haveasuitableslingingconguration
and are protected from sharp edges.
Itismostimportantthatallliftinggearincludingslings,hooks,wire
ropes,pendantsandmaterialboxesareperiodicallyinspectedfor
damage and wear. The period between inspections may depend on
the severity of use with the exception of:
chainslings,whereinspectionsmustnotexceed12months
syntheticbreslings,whereinspectionfordamagemustbe
undertaken before each use and full inspection at least every
threemonths.Refertosection9ofAS 1353 .2: 1997 Flat
synthetic webbing slings, part2:Careanduseforinspection
itemsandsection11forDiscardCriteria.
Documented maintenance records for the lifting gear should be
available for inspection on-site.
4.4.4 liti w atia
Crane-liftedloadsmustbeslungandsecuredsothattheload
(oranypartofit)cannotfall.
Weightsofwall,liftorcolumnformsshouldbeprovidedon-sitewith formwork documentation and made available for inspection
by all interested parties.
SLLsmustbeclearlymarkedonbins.
Liftingboxesintendedforliftingpeoplemustbedesign
registeredwithSafeWorkSAandsuitablyconstructedforother
material being lifted.
Fourchains(oneineachcorner)mustbettedtoliftboxesto
maintain stability.
Liftingboxesmustbeinspected,maintained,andinspectionrecords kept.
Specically-designedliftingboxesshouldbeusedtoliftsmaller
components(e.g.spigots,U-heads,baseplatesandcouplers).
Boxesmusthaveenclosedsidesorrobustmesh(withopenings
lessthantheminimumsizeofmaterialsbeinglifted).
Loadscontainedwithinliftingboxesshouldbesecured
against movement.
Materialsmustnotbestackedhigherthanthesideofthebox
unless they are adequately secured.
Formworksupportframesmusteitherbetiedtogetheror
secured with lifting slings wrapped around the load.
Loadsofjoistsorbearersshouldbestrappedtogether
before lifting.
Taglinesmustbeusedtocontrolloadsandforms,andmust
bexedtotheload,nottheliftinggear.
Formplyloadsshouldbestrappedtogetherandliftedina
atposition.
Ensure,wherepossible,thatallloadsaresupportedondunnage
and the load is uniformly distributed over the supporting surface.
Priortoliftinganyitems:
removeanywasteconcreteetc.fromformsoranyother
materials or equipment to be lifted to ensure the waste does not
fall onto people below
inspectallloadscloselytoensureallloosematerialsandtools
have been removed.
4.4.5 liti
Chainslingsattachedtolugsorholescutintopartofaloadareoften
usedtoliftbins,wall,liftwellorcolumnforms(insteadofwrapping
theliftingslingsaroundtheload).Informationverifyingthestructural
adequacy of the lifting points must be available.
Anengineermustverify:
thestructuraladequacyoftheliftinglug
themeansofattachmenttotheload(usuallyweldedorbolted).
4.5 use of lADDers
Laddersmustbesecuredatthetoporbase,orwhenthisis
impractical,heldrmlyatthebasebyanotherperson.
Wherepracticable,alternativestoladderssuchasworkplatformsor
stairaccesssystemsmustbeused.Fixedorpermanentladdersmustcomply withAS 1657 Fixed platorms, walkways, stairways and
ladders Design, construction and installation.
8/22/2019 Formwork Guide
22/3721
Whereladdersareprovidedasaccesstoalivedeck:
theymustextendatleastonemetreabovetheaccessed
surface,besecuredagainstmovementandbesetuponarm,
level surface
theymustbeofindustrialstandardwithaloadratingofat
least 120 kg
singleandextensionladdersmustbeplacedatanangleof
between70degreesand80degreestothehorizontal
(4up,1outrule),exceptinsomeraresituationswherethis
is impractical
singleladdersmustnotexceed6.1minlengthandextension
laddersmustnotexceed7.5m.
Otherissuesregardingthesafeuseofladdersinclude:
metalormetalreinforcedladdersmustnotbeusedinthevicinity
ofliveelectricalequipment.TheOfceoftheTechnicalRegulator (OTR)providesinformationoncompliancewithsafeworking
distances in the vicinity of live electrical wires
nevertouchaladderthatisincontactwithelectricalpowerlines
apersonsfeetmustalwaysbemorethan1mfromthetopof
the ladder
laddersarenottobeusedonscaffoldingorelevatedwork
platforms to gain extra height
laddersmustnotbepositionedaboveoradjacenttoopeningsor
edgeswhereapotentialfallcouldoccur.Aworkplatformwith
edge protection should be used instead
laddersshouldnotbeusedinaccesswaysorwherethereis pedestrian,vehicularormobileplanttrafcunlessarisk
assessment has been undertaken and other precautions have
been considered
alwaysmaintainthreepointsofcontactwhenusingladders.
5. spia qit wa ad
5.1 brAcIng for WInD loADIng
Wallandcolumnformsmustbedesignedtowithstandalllive
anddeadloads,includingwindloadpriorto,during,andafterthe
concrete pour. The bracing and forms must not be removed from
thecastelementuntilitissufcientlymaturetosafelywithstand
potential impact loads and wind loads.
Priortostripping,anengineerorothercompetentpersonmust
providewrittencerticationthattheformworkcanberemoved.
Bracingmustbedesignedtosuititsapplicationandveriedbythe
designer(refertosection2.2.1).Bracingelementsmustbedesigned
and installed to resist both positive and negative wind generatedloads.Bracinganchorsshouldpreferablybecast-intypeorthrough-
boltsthatextendthroughbothsidesoftheanchoringmedium.
Drill-inanchorsofthefollowingtypemaybeused,providedtheyare
installedinaccordancewiththemanufacturersinstructions:
undercuttypeanchorthatdoesnotrelyonfrictiontofunction
expansionanchorsofthehigh-loadslip,torquecontrolledtype
coilbolts.Thecorrectoperationofcoilboltsisgreatlydependent
on whether they are installed in accordance with a
manufacturersspecications(e.g.drillingthecorrectsizedhole
andapplyingthecorrecttorqueinconcreteofadequatestrength).
Drill-intypeanchorsmayhaveaspecicinstallationtorqueset
requirement to function correctly. Torque measurements should be
madeusinganaccuratelyadjustabletorquewrench.Analternative
method that may be used to verify the torque could be a calibrated
rattlegun.Recordsverifyingthesettingtorqueforalldrill-intype
anchorsshouldbeavailableon-site.Manufacturersnormallyspecify
the minimum distance from a concrete edge that an expansion
anchor may be installed.
5.2 Access PlATforms
Mobilescaffolding,purposebuiltworkplatformsorelevatingwork
platforms may be suitable in providing the essential safe access to
elevatedworkareasfordogmen,steelxersandconcreters.Edge
protection must be provided on any access platform.
Platformsmustbedesignedtoprovidesufcientaccessandworking
spaceforthenumberofpersonnelrequiredforspecictasks,and
must be positioned at a height and distance from the form so as to
minimisereachingandstretchingmovementsandlimitapersons
necessary exertion.
Concretepouringsystemsmustprovideadequatesafeworking
space,withedgeprotectionprovided,forallworkers.
Castorsonmobileworkplatformsmustbelockedatalltimesexcept
when they are being moved.
Allplatformsmustbedesignedforstabilityandresistancetoany
sideloadingthatmaybeappliedduringaconcretepour.Lightweight
aluminium scaffolding may not have adequate stability when
subjected to side loading and may require additional bracing.
5.3 lIfTIng meTHoDs
Wallandcolumnformsmayonlybeliftedwithapositivelifting
system,suchasliftinglugsorbywrappingliftingslingsaround
theformsuchthattheformcannotslipoutoftheslings.Purpose
designedliftinglugsmustbeusedwhereverpracticable(referto
section4.4.5).
Anengineermustprovidedocumenteddesignsforwallandcolumn
formliftingpoints,andthedesigndocumentationshouldbeavailable
on-site.Whereliftinglugsareattachedtotheform,anengineermust
specifythexingorwelddesign,andthemanufacturermustensure
and certify that the attachment or weld complies with the design
requirements.
8/22/2019 Formwork Guide
23/3722
Formingliftingpointsbycuttingholeswithoxy-acetylenetorchesis
unacceptable and must not be used as:
theloadcarryingcapacitycannotbeguaranteed
itmaydifculttoattachliftinggear
positioningoftheholemaybeinaccurate
theformmaybedamaged.
6. spia qit ip ad p
Thissectionappliestoslipforms,jumpformsandcrane-liftedforms
that incorporate working platforms and enclosed cells in which
people are required to work.
Slipformsandjumpformsaretermsgiventoself-climbingformwork
systemsspecicallyintendedtoconstructconcreteservicecores,walls and columns in high rise buildings and other concrete
structuressuchassilosandchimneys.Inslipforms,theclimbing
is usually carried out continuously during the concrete pour which
maybecompletedtofullheightinonepouringoperation.Withjump
forms,theclimbingisdoneinsteps,liftingthecompleteformunitto
thenextlevelfollowingeachconcretepour.Thetermclimbingform
isalsousedtodescribeeitheraslipformorjumpform.Climbing
operations are usually powered by hydraulic rams or electric motors
connected to climbing feet or screw shafts.
Slipformsandjumpformsusuallyconsistofanumberofdecksand
mayalsobettedwithtrailingscreensthataresuspendedfromthe
form.Aswithperimeterscreens,trailingscreensmay:
provideedgeprotection
preventmaterialsfromfalling
providesupportforworkplatforms,oracombinationof
these uses.
Notwoslipformsorjumpformswillnecessarilybeidentical,astheir
designwillbebasedonthesizeandcongurationofthestructureor
building under construction.
The work systems and layout of some crane-lifted forms may also
be similar to those associated with slip forms and jump forms. This
may be the case for crane-lifted forms provided for the inside of lift
shafts.Whilemostoftheinformationinthissectionappliestoslip
formsandjumpforms,someoftheprinciplesmayalsoapplyto
crane-lifted forms.
Whendesigningandoperatingthesetypesofformsystems,the
following issues must be addressed:
providesafeaccesstoallareasandworkplatforms
controlrisksassociatedwithworkingatheight developsafeworkmethodstatementsandusingthemtotrain
workers in the safe operation of slip and climb form systems
providesufcientworkingspaceandheadroom
specifyandprovidesafeworkmethodstatementsformanual
handlingofshuttersandothercomponents,e.g.theuseof
cranes to lift shutters and provision of safe access for workers
attaching slings to shutters
ensureadequateventilationandlightinginallworkareas
provideadequateamenitiesforworkersgiventhatslipformoperations often continue for extended shifts
alwaysuseHotWorkPermitsforslipformandjumpformsystems
ensuresufcientreextinguishersareprovided
ensureemergencyprocedures,includingfortheretrievalofan
injured or incapacitated person from any work area located
withinthestructurearedeveloped,implementedandtrialled.
It is acknowledged that it may not be practicable to provide an
access system and working environment on a jump form or slip
formthatisofthesamestandardaselsewhere.However,anyone
incontrolofaproject,taskorworkersmustcomplywiththeirobligationsundertheOHSWAct.
6.1 Access AnD egress
Accesstoslipformandjumpformsystemsmaybeprovidedina
variety of ways including one or more of the following:
personnelandmaterialhoistsonthebuilding
permanentstairsystemsinthebuilding
atrailingstairsystemsuspendedfromtheslipformorjumpform
atrailingladdersystem.
Atrailingstairsystemispreferabletoaladdersystemasitiseasier
toascendanddescend,andemergencyevacuationisgenerallysafer
and easier on a stair system. The access area between the trailing
accesssystemandthebuildingmustbeclearoftriphazardsand
thereshouldbenogapsexceeding50mmwidebetweenplatforms.
The formwork designer must ensure that a trailing access system is
designed for additional loads that could be applied in an emergency
evacuation situation. The design must ensure that not only the
strengthoftheformsystemitselfisadequate,butalsotheformwork
structure safely supports any applied loads from the access system.
Atrailingstairaccesssystemshouldbedesignedforaloadof
atleast2.5kPaunlessthedesignerspeciesotherwise.Where
thedesignerspeciesalesserliveloadthan2.5kPa,thefollowing
applies:
asignstatingthemaximumloadlimitmustbexedtothe
stairs in a visible position
writtenproceduresmustbeimplementedtoensurethetotalload
limit is not exceeded.
Laddersmustbesecuredinplaceandbeplacedatanangle
between70and80degreestothehorizontal,wherethisispractical.
Accessopeningsforladdersonworkingdecksshouldbeprovided
withtrapdoorsthatareclosedwhennotinuse,easilyopenedfrom
above,anddonotcreateatriphazardonthedeck.
8/22/2019 Formwork Guide
24/3723
Accesswaysshouldbekeptfreeofmaterialsandrubbishtoprevent
objects falling to the level/s below.
6.2 Work PlATforms
Division13PreventionoffallsoftheOHSWRegulationsspecies
requirements for work platforms. These requirements also apply to
slipformsandjumpforms.However,thefollowingpointshighlight
specicissuesthatmayapply:
Whenplacingsteelorpouringconcreteintoaform,controls
must be implemented that prevent a person falling into or from
the form. The risk of this is higher when the form is greater
than225mmwidepriortoplacementofreinforcingsteel.
Workersmustalsobeprotectedfromtheriskofbeingimpaled
onprojectingreinforcingbarsorotherobjects.Suitablecontrols
may include edge protection on the internal side of the working
platform,orreinforcementmeshtemporarilyplacedontopof theform,enablingthesteeltobefedthroughthemesh(see
Figure12).
Thedesignandconstructionofplatformsmustincludepositive
xedsecuritysothatjammingormovementcannotoccurunder
eccentric loads e.g. where work platforms have a trailing screen ononesideandaresupportedbyabuildingparapetontheother,
uplift may occur from wind loading or where a platform is not
levelandisunsecured.Ifthisoccurs,theplatformmayjamor
otherwisemoveundertheunbalancedload,causingaperson
to fall.
Whereindividualcellsofaformareclimbedatdifferenttimes,
edge protection must be provided separately on each cell.
Safeworkmethodstatements,developedforallhigherrisk
aspectsofslipformorjumpformsystemsandaccesssystems,
will assist in ensuring safe systems are implemented and provide
a sound training aid for workers engaged in this activity.
6.3 TrAIlIng screens AnD PlATforms
Trailing screens can provide edge protection and a means of
preventing falling objects. They can also be designed to support
lower,suspendedworkingplatformsforrepairingorpatching
concrete,andtoprovideaccessforanyoneclimbingtheform.The
formworkdesignerwillneedtospecicallyaddressanddocumentall
issues for which the trailing screen system is designed. The design
must address the following:
Theremustbeasuitabledesignloadingforanyplatformson
thetrailingsystem.Asaguide,platformsmustbedesignedto
supportaminimumloadof2.5kPa.Adesignermayreduce
this if the number of people is strictly limited and controls are
implementedon-sitetoensurethespeciedloadisnot
exceeded.Ifthedesignloadislessthan2.5kPa,thismustbe
statedindocumentationkepton-siteandsignsmustbexedto
the platforms stating the maximum load permitted in kilograms.
Sitepersonnelmustbemadeawareofandcomplywiththe
maximum loading that applies to the trailing platform.
Strategiesmustbeimplementedtoadequatelycontrolthe
riskfromfallingmaterials(seesection5forfurtherguidance).
Allplatformsmustbesecuredtopreventupliftoranyother
unplanned movement.
Ariskassessmentofaformsystemmustincludetheneedfor,
anduseof,laddersandedgeprotection.Thesystemmustmeet
therequirementsoftheOHSWRegulations.
Apersonmustnotrideontrailingplatformswhiletheplatformsare being crane-lifted. If access or work is required whilst a
cranesupportsthetrailingplatform,anotherworksystemmust
be devised. This could involve another crane with a registered
workbox,oraseparateaccessscaffoldsystem.
AnyworksystemchosenmustcomplywiththeOHSW
Regulationsandincludesafeworkmethodstatementsbasedon
riskassessment,withriskcontrolstrategiesbasedonapplication
of the hierarchy of control.
6.4 clImbIng THe form
Climbingisusuallycarriedoutusingaseriesofclimbingdevices
set up to lift at the same time and at the same rate. If the lifting
system is not properly synchronised the form may become wedged
onthestructure,orstructuralmembersmaybeoverloadedand
become unstable.
There should be a systematic approach to ensure that the form
remains within level tolerances during the climbing process. The
system may be automated or may rely on operators stopping each
individualdevicecontrollingtheclimbingprocess.Whicheverprocess
isused,thefollowingmustbeobserved:
Asafeworkmethodstatementmustbedevelopedtotrain
personnel and manage the climbing process.
Figure 12 Mesh used as all protection
on wall pour
8/22/2019 Formwork Guide
25/3724
Onlythoseworkersdirectlyinvolvedwiththeclimbingprocess
may be on the form during the climb.
Anypotentialniporshearpointswhereapersoncouldbeinjured
duringtheclimbmustbeidentiedandcontrolled.
Allobstructionsandlooseitemsontheformaretoberemoved
priortoclimbing.Aninspectionchecklistandsign-offprocedurefor this should be implemented. Items typically left on forms
includeZ-bars,ferrulebolts,insertanchors,coversand
hand tools.
Itisimportanttoensurethedifferentpartsoftheformremain
level during the climbing process.
Electricalcables,waterandotherpiped