Formwork-Code and Practice
Formwork-Code and Practice
Formwork-Code and Practice
This Queensland code of practice was preserved as a code of practice under section 284 of the Work Health and Safety Act 2011. This code was varied by the Minister for Education and Industrial Relations on 27 November 2011 and published in the Queensland Government Gazette on 2 December 2011. This preserved code commences on 1 January 2012.
PN11175
The State of Queensland (Department of Justice and Attorney-General) 2011 Copyright protects this document. The State of Queensland has no objection to this material being reproduced, but asserts its right to be recognised as author of the original material and the right to have the material unaltered. The material presented in this publication is distributed by the Queensland Government as an information source only. The State of Queensland makes no statements, representations, or warranties about the accuracy or completeness of the information contained in this publication, and the reader should not rely on it. The Queensland Government disclaims all responsibility and all liability (including, without limitation, liability in negligence) for all expenses, losses, damages and costs you might incur as a result of the information being inaccurate or incomplete in any way, and for any reason.
Contents
1. Introduction ...................................................................................................... 5 1.1 Falls from heights .............................................................................................. 7 1.1.1 Unsuitability of harness systems for formwork activity ............................. 7 2. Design ............................................................................................................... 7 2.1 Safe design of buildings in relation to formwork................................................. 7 2.1.1 Build-ability............................................................................................... 7 2.1.2 Materials .................................................................................................. 8 2.2 Formwork systems............................................................................................. 9 2.2.2 2.2.3 2.2.4 2.2.5 Formwork design certification requirements........................................... 10 Documentation....................................................................................... 11 Design variations ................................................................................... 12 On site coordination and verification ...................................................... 13
3. Coordination and administration.................................................................. 14 3.1 Work program .................................................................................................. 14 3.2 Housekeeping.................................................................................................. 14 3.2.1 Access ................................................................................................... 14 3.2.2 Material storage ..................................................................................... 15 3.2.3 Rubbish storage and removal ................................................................ 15 3.3 Training............................................................................................................ 16 4. Work systems................................................................................................. 16 4.1 Formwork erection traditional systems.......................................................... 16 4.1.1 Foundations ........................................................................................... 17 4.1.2 False deck.............................................................................................. 17 4.1.3 Erecting frames...................................................................................... 18 4.1.4 Installing bearers.................................................................................... 19 4.1.5 Fall protection from the formwork deck .................................................. 19 4.1.6 Laying formply on the deck .................................................................... 20 4.1.7 Cantilevers ............................................................................................. 22 4.1.8 Penetrations........................................................................................... 23 4.1.9 Working areas for steel fixers and others............................................... 23 4.1.10 Changing floor levels ............................................................................ 24 4.2 Formwork erection modular formwork systems ............................................ 24 4.2.1 Training .................................................................................................. 25 4.3 Stripping formwork........................................................................................... 25 4.3.1 4.3.2 4.3.3 4.3.4 4.3.5 Safe work method statement ................................................................. 25 Bond reduction....................................................................................... 25 Certification prior to stripping ................................................................. 25 Exclusion zone....................................................................................... 26 Drop stripping......................................................................................... 26
Loading materials during formwork construction.................................... 27 Access for persons slinging loads.......................................................... 27 Lifting gear ............................................................................................. 27 Lifting formwork materials ...................................................................... 28 Lifting lugs.............................................................................................. 28
4.5 Use of ladders.................................................................................................. 29 5. Falling objects ................................................................................................ 29 5.1 Prevent the object from falling ......................................................................... 30 5.1.1 Perimeter containment screening .......................................................... 30 5.2 Building step-ins .............................................................................................. 31 5.3 Gaps ................................................................................................................ 31 5.4 Prior to lifting................................................................................................... 32 6. Health concerns ............................................................................................. 32 6.1 Noise .............................................................................................................. 32 6.2 Dust ................................................................................................................ 33 6.3 Manual tasks.................................................................................................... 33 6.3.1 Control measures for manual tasks ....................................................... 33 7. Special requirements for wall and column forms ....................................... 34 7.1 Bracing for wind loading ................................................................................. 34 7.2 Access platforms ............................................................................................ 35 7.3 Lifting methods................................................................................................ 35 8. Special requirements for slip forms and jump forms ................................. 36 8.1 Access and egress ......................................................................................... 36 8.2 Working platforms and penetrations ............................................................... 37 8.3 Trailing screens and platforms........................................................................ 38 8.4 Climbing the form............................................................................................ 38 8.5 Training........................................................................................................... 39 8.6 Health issues and amenities ........................................................................... 39 8.7 Engineering issues ......................................................................................... 39 8.8 Emergency issues .......................................................................................... 40 Appendix 1: Dictionary ....................................................................................... 41 Appendix 2: Sample engineers certification letters ........................................ 43 Appendix 3: Construction checklist .................................................................. 45 Appendix 4: Sample structural (pre-pour) certificate ...................................... 47 Appendix 5: Defects commonly found in formwork systems ......................... 48
1. Introduction
This Formwork Code of Practice 2006 is an approved code of practice under section 274 of the Work Health and Safety Act 2011 (the Act). An approved code of practice is a practical guide to achieving the standards of health, safety and welfare required under the Act and the Work Health and Safety Regulation 2011 (the Regulation). A code of practice applies to anyone who has a duty of care in the circumstances described in the code. In most cases, following an approved code of practice would achieve compliance with the health and safety duties in the Act, in relation to the subject matter of the code. Like regulations, codes of practice deal with particular issues and do not cover all hazards or risks which may arise. The health and safety duties require duty holders to consider all risks associated with work, not only those for which regulations and codes of practice exist. Codes of practice are admissible in court proceedings under the Act and Regulation. 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 the circumstances to which the code relates. Compliance with the Act and Regulation may be achieved by following another method, such as a technical or an industry standard, if it provides an equivalent or higher standard of work health and safety than the code. An inspector may refer to an approved code of practice when issuing an improvement or prohibition notice. How is the code organised In providing guidance, the word should is used in this Code to indicate a recommended course of action, while may is used to indicate an optional course of action. This Code also includes various references to provisions of the Act and Regulation which set out the legal requirements. These references are not exhaustive. The words must, requires or mandatory indicate that a legal requirement exists and must be complied with. Who has duties? A person conducting a business or undertaking has the primary duty under the Act to ensure, as far as reasonably practicable, that workers and other persons are not exposed to health and safety risks arising from the business or undertaking. Officers, such as company directors, have a duty to exercise due diligence to ensure that the business or undertaking complies with the Act and Regulation. This includes taking reasonable steps to ensure that the business or undertaking has and uses appropriate resources and processes to provide and maintain a safe work environment. Workers have a duty to take reasonable care for their own health and safety and that they do not adversely affect the health and safety of other persons. Workers must comply with any reasonable instruction and cooperate with any reasonable policy or procedure relating to health and safety at the workplace.
Consulting workers Consultation involves sharing of information, giving workers a reasonable opportunity to express views and taking those views into account before making decisions on health and safety matters. The Act requires that you consult, so far as is reasonably practicable, with workers who carry out work for you who are (or are likely to be) directly affected by a work health and safety matter. If the workers are represented by a health and safety representative, the consultation must involve that representative. You must consult your workers when proposing any changes to the work that may affect their health and safety. Consulting, cooperating and coordinating activities with other duty holders The Act requires that you consult, cooperate and coordinate activities with all other persons who have a work health or safety duty in relation to the same matter, so far as is reasonably practicable. Sometimes you may share responsibility for a health and safety matter with other business operators who are involved in the same activities or who share the same workplace. In these situations, you should exchange information to find out who is doing what and work together in a cooperative and coordinated way so that all risks are eliminated or minimised as far as reasonably practicable. Further guidance on consultation is available in the Work Health and Safety Consultation, Coordination and Cooperation Code of Practice. Hazards associated with work involving the erection, alteration and/or dismantling of formwork include: formwork collapse (before, during and after placement of concrete) falls from heights slips and trips falling objects noise dust, and manual tasks. To properly manage risks, a person must identify hazards assess risks that may result because of the hazards decide on control measures to prevent, or minimise the level of, the risks implement control measures, and monitor and review the effectiveness of the measures. Control measures must be implemented in an order of priority and implemented before work commences. The following example illustrates the order of priority where there is a risk a person could fall.
Design and planning Eliminate the risk during the design and planning stage. Where this is not practical, prevent a fall For example, through the use of edge protection, a cover placed over an opening. Where this is not practical, arrest a fall and prevent or minimise injury from the arrested fall For example, through the use of a fall arresting platform. As a last resort and/or to complement higher order control measures implement administrative controls.
2.
Design
The Work Health and Safety Act 2011 provides that the designers of structures to be used as workplaces have duties for workplace health and safety.
Some of the measures that should be considered by the designer of the building to minimise exposure to risk of injury during the construction of formwork include: Reducing variations in the floor depth, that is, construct a floor so that it has one consistent depth. Decks that are a consistent depth are easier to erect than variable depth floors and reduce the risk of injury. Deeper beams introduce drop downs into the floor. Reducing the number of columns required, that is, where columns exist, design the columns so capitals or dropdowns dont exist. Reducing cantilevered floor sections. Planning for manual tasks. Consideration must be given to the suitability of the design of different formwork systems that will reduce manual tasks risks, including: - table forms - systems with lighter weights of materials to be handled - methods of formwork erection, alteration and dismantling - improved access and egress for workers and movement of materials and equipment, and - 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. As illustrated in Diagram 1, decks of a consistent depth may result in savings in concrete and steel but will result in additional labour and material costs. Decks of a varying depth introduce a greater quantity of cantilevered beams and joists, which contribute to the risk of a person falling.
2.1.2 Materials
All materials and equipment used in formwork construction must be fit for the intended purpose and meet design specifications. Materials and equipment must be designed to conform to relevant
Australian Standards or equivalent. Materials and equipment must be manufactured in accordance with a quality assurance system that ensures compliance with the design specification. Evidence must be kept on site, which verifies that formply sheets conform to Australian or equivalent standards. Such evidence may include: a purchase order which details the specifications of the formply sheets ordered, or that the formply sheets being marked in accordance with Australian Standards (see AS/NZS 2269).
Shade cloth used on screens, signage and outside screens will increase the effective wind loading of an open structure. The geographical location of the construction site will also have a bearing on the severity of wind on the structure. Wind generally has less effect in built up or hilly areas. AS 1170.2 Structural Design Actions - Wind actions specifies four different terrain categories that must be taken into consideration by a designer of formwork as well as basic wind speeds for different zones in Australia. There are three regions for Queensland: Region A (normal) most of Queensland excluding coastal areas (includes Toowoomba and Mt Isa) Region B (intermediate) Queensland coastal areas south of Bundaberg and a narrow band behind region C (includes Brisbane and all of Gold Coast and Sunshine Coast) Region C (tropical cyclones) all coastal areas north of, and including, Bundaberg. Region C has the greatest wind speeds. There are a number of other factors that need to be considered by a designer of formwork when calculating wind pressure on wall and column forms and the resultant number of braces and size of anchorage point required. The number of braces for securing a column or wall form is not to be considered to be necessarily in direct proportion to wind speed. Wind pressure will vary as a function of the square of the wind speed. A small increase in wind speed produces a much larger increase in pressure and a much larger increase in the number of braces or size of brace anchors required.
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standard formwork frames which have a known tested loading capacity spaced at no more than the recommended distances apart for a normal floor thickness with bearer, joists and formboard on top of them, and specially manufactured and designed formwork systems with proprietary formwork components and rated load calculations in line with the manufacturers specifications.
A basic formwork system is limited by the following conditions: The height of the formwork must not be greater than or equal to 6 metres to the soffit of the new floor from the supporting floor. Walls and columns must not be greater than 6 metres free standing from the floor on which the formwork will be supported. Where any of these conditions occur, the system is classified as a non-basic formwork system, and this code requires that an engineer is the only person who may certify such a formwork system. Non-basic formwork systems Formwork systems which exceed the description of a basic formwork system are, for the purposes of this code, categorised as non-basic formwork systems. This code requires that an engineer is the only person who may certify: the design of all temporary or permanent formwork structures categorised as non-basic formwork systems, and any back propping used for either basic formwork systems or non-basic formwork systems. For the purposes of this code, it is understood that non-basic formwork systems include formwork structures higher than three frames or 6 metres (or three times the least base width).
2.2.3 Documentation
Formwork drawings Formwork drawings must explain: plans, elevations and sections to show the general arrangement of the formwork and to identify and locate all members and components including bracing the maximum point loadings to be applied the component types and spacings the maximum jack extensions the bearer and joist timber type, the dimensions and spacings the prop sizes and maximum extensions the methods for tying the structure together and spacing between ties (if required), and the formply size. Where eccentric loading is to be applied to U-heads (i.e. single bearers are positioned to one side of the U-head), the formwork drawings must state that this is permitted. Other formwork documentation The following information must also be provided in the formwork documentation: details sufficient to fully describe important or unusual features of the design reference to documentation for proprietary items safe work method statements for the erection and stripping of the formwork assembly the areas of the forms designed to carry stacked loads acceptance criteria for single use formwork requirements of the project documentation relating to formwork
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method of provision for field adjustment of the forms prior to and during concrete placement where required, location of weep holes, vibrator holes, clean-out holes and inspection openings sequence of concrete placement, including direction of intended pour on raking or sloping surfaces(e.g. car park ramps and minimum elapsed time between adjacent placements) wrecking strips and other details relating to stripping of the forms design assumptions, including those related to strength, stability and stiffness footing design assumptions, such as foundation material description, safe bearing value, limitations on settlement during erection of formwork, placement of concrete and dismantling of formwork. Reference to information sources such as geotechnical reports must also be included preparation of the foundation, such as filling, compaction and drainage footing details, such as type and size of footings, level of soffit, concrete strength, reinforcement, specification and details of site filling or compaction, and precautions against washouts engineer certification of non-proprietary equipment vertical pour rates, and methods of securing single or multiple props.
Project documentation Project documentation must include the following information: minimum stripping times and stripping procedures and requirements for health and safety any limitations on the magnitude and location of stacked materials and minimum strength of concrete to be achieved prior to materials being stacked requirements for the minimum number of levels of supports relative to the type of formwork, timing and sequence of its use, the anticipated time between construction of subsequent floors and the expected ambient temperature for multistorey structures limitations on the use of the permanent structure for the restraint of formwork details of and information on the effect of post-tensioning procedures on the formwork and any special procedures to be adopted in the stripping of formwork location of any mandatory joints and any special procedures for locating other joints sequence of placement of concrete requirements for propping of any composite construction details of the cambering of any slabs or beams design loads for the permanent structure details of any inserts, water stops, specially formed shapes or penetrations to be constructed, the location and details of which are critical to the serviceability of the permanent structure any known information about the foundation which is relevant to the design of the footings for the formwork assembly information about any permanent formwork systems, together with any limitations on deflections and any special requirements for their erection and concreting information on any architectural or structural component details to be cast into the structural concrete details of fall and edge protection, that is, perimeter scaffolding, and details of back propping that may be required and minimum time intervals between concrete pours.
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certified in writing by a formwork designer or engineer as being acceptable (that is, complying with AS 3610 Formwork for concrete), if the formwork designer or engineer can verify this is the case, and altered in accordance with the written directions of a formwork designer or engineer in order to comply with AS 3610, within a time frame specified by the formwork designer or engineer.
Potential variations include: a reduced number of formwork frames under the formwork deck different types of braces or props to the ones indicated on the formwork drawing different types and/or quantities of ties on the formwork structure increased spans on members supporting the formwork deck variations in the back-propping system specified by an engineer, and connections between traditional formwork and modular formwork.
action has occurred prior to the concrete pour including any items referred to an engineer for certification and modified as instructed by an engineer. A pre-pour inspection ought to focus on such matters as: correct spacing of frames, props and timbers correct joist and bearer sizes acceptable jack extensions, and adequate bracing to ensure stability. An effective quality control system must be implemented for the construction of formwork. A prepour inspection is a check to assist in ensuring the specifications of the designer of the formwork have been complied with. A pre-pour inspection ought to be a part of any quality control system. Sign-off by an engineer, formwork designer or competent person is required following the final prepour inspection. A sample pre-pour structural certificate is provided at Appendix 4. Appendix 5 illustrates some of the more common defects which are likely to occur in a formwork system. This list is intended to give guidance to a competent person and should not be considered to be exhaustive. In any individual case, some items will be less important than others and only a competent person with appropriate experience can assess their relative importance.
3.2 Housekeeping
The Work Health and Safety Regulation 2011 places duties on persons for housekeeping practices. Formwork construction because of its constantly changing work environment, restricted access through frames and formwork supports and a large volume of material and waste, requires ongoing monitoring of housekeeping practices.
3.2.1 Access
The Work Health and Safety Regulation 2011 requires that there be clear access to and from the workplace. Clear access is important for the safe movement of materials, equipment and persons on site. Designated access ways must be provided. Persons must be instructed to use the access ways and keep them clear of any rubbish, plant or materials. In some situations, it may be necessary to use
Formwork Code of Practice 2006 14
hazard taping or other visual methods to clearly show where access ways are located. This is particularly important where access is required through formwork frames. Emergency access and egress must be considered and provided to all parts of the workplace where persons are required to work.
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3.3 Training
All persons who may be exposed to workplace health and safety risks resulting from formwork construction must be provided with information and training that is specific to the formwork system that is being used. Such training and information must include details of: the formwork system, tasks, activities and components the way the manufacturer or designer of the formwork system intended the system to be erected, installed, used, moved, altered or dismantled specific training and information required to undertake or participate in specific tasks or activities control measures to minimise exposure to the risks, correct use of controls, and how to ensure they are kept in full working order safe working procedures, including the use of mechanical aids and devices, where appropriate how to use and maintain equipment, including any specific conditions and prohibitions on the use of equipment. Reference must be made to operators' manuals any special safety information needed such as safety precautions for working under certain conditions personal protective equipment required, including instruction in fitting, use, cleaning, maintaining and storing this equipment, and details of how accidents have occurred in the past involving the same work process(s). Persons involved in formwork activities must also be provided with more general workplace health and safety information and training including: the effects of noise on their hearing and health Queenslands workplace health and safety legislation, including relevant parts of this code of practice the workplaces health and safety policies, and relevant procedures and safe work method statements the risk management process inspection and maintenance programs in place at the workplace how to access information such as manufacturer's instructions about hazards, and emergency procedures, including persons with specific emergency roles and responsibilities.
4. Work systems
4.1 Formwork erection traditional systems
The Work Health and Safety Regulation 2011 describes what must be done where there is a risk a person could fall. The Work Health and Safety Regulation 2011 requires the preparation of a safe work method statement for high-risk construction activity. The erection of formwork must comply with regulatory requirements for the erection of scaffolding. Formwork, like scaffolding, must be erected systematically and tied in progressively to stabilise the structure. Where a person is to install joists from underneath, the vertical distance between the formwork deck and the false deck can be increased. This is illustrated in Diagram 2 below.
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Diagram 2 - Worker erecting formwork on two planks A person must be provided with a working platform of at least 450 mm wide (i.e. two planks). It is not acceptable for a person to stand on a single bearer or a single plank.
4.1.1 Foundations
Formwork must be erected on a stable base to prevent the risk of collapse. Suspended slabs must be able to safely support loads that may be applied by the concrete pour, workers and crane lifted loads. Base plates must be provided under props and standards on formwork frames unless the prop or standard has an integral foot or an engineer documents that a base plate is unnecessary. Sole boards designed to suit the ground conditions should also be used under props and standards on natural ground, unless an engineer states otherwise. Frames and props must be located on a firm base, which is ground that will not subside, fail or get washed away. The principal contractor is responsible for providing all information on ground conditions to the engineer or formwork designer.
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Diagram 3 A false deck The false deck must be designed and installed to have adequate strength to support persons required to stand on the deck and any materials or persons that could fall onto the deck or be placed on the deck. The deck must be able to withstand: a point load of 2 kN distributed over an area of 100 x 100 mm (2 kN is approximately equivalent to a mass of 200 kg) a uniformly distributed load of 2 kPa which is equivalent to a mass of 200 kg per square metre. When considering the design of the deck for the erecting, altering and/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 must allow access for a person during stripping.
other edge protection) is installed progressively and as soon as enough material has been raised up, additional control measures to prevent a fall occurring do not have to be provided. Many conventional formwork frames consist of diagonal braces that cross in the middle. While these braces are not considered to be suitable edge protection for a completed formwork deck, they may provide reasonable fall protection during frame erection. This is only the case where braces are installed in a progressive manner as soon as the braces are handed up to a person. As the height of formwork frames increase, there is a greater need to provide lateral stability to the frames. All framing must be carried out so that it complies with on site design documentation and any manufacturers requirements.
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The most effective means of providing edge protection on a completed formwork deck is by providing perimeter scaffolding. Scaffolding is erected prior to the formwork and prevents workers falling off the completed deck. The main advantage of this system is that persons are not required to install edge protection on the perimeter of the formwork deck and are therefore not exposed to a risk of falling. The other advantage is that edge protection for persons installing the final perimeter formply sheets is already in place. Where scaffolding over four metres in height is provided, any erection, dismantling or alteration of the scaffolding must only be undertaken by certified and authorised scaffolders. Any scaffolding components must be replaced following removal. Gaps between a completed floor and scaffolding, that may exist after the formwork support system is removed, must be covered where there is a risk of a person or materials falling through the gap. In some rare situations, it may be impractical to provide perimeter scaffolding. If this is the case, the work system used to install perimeter edge protection on the deck must ensure that a control measure is provided to ensure against the risk of a fall. The use of harness systems is discouraged, because it does not provide an adequate and impractical control for the risk of a fall from height. In some situations, edge protection can be substituted with an alternative measure provided this measure prevents a person falling from the edge. One alternative is the provision of a barricade 1.8 metres back from the edge with clearly visible keep out signs.
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Diagram 4 Maximum spacing of timbers around worker where false deck is over 2 metres below Typical work system for a leading edge The following work system may be used by persons to construct the formwork deck for typical or multi-level construction. The work system may be used irrespective of the distance to the false deck or floor below, but is specifically intended for situations where the vertical distance below the deck being constructed is greater than two metres. Place bearers on the U-heads of the formwork frames from the working platform provided immediately below. Secure bearers to prevent movement (i.e. by nailing to or wedging in the U-heads) before joists are placed on top. No eccentric (un-centred) loads should be applied to the U-heads. Place joists on the bearers in a progressive manner from the work platform located directly below the area to be worked on, and spaced at 450 mm centres (maximum) or so that the gap between joists does not exceed 400 mm. Cantilevered bearers and joists must be secured against uplift prior to persons being supported by them, if the cantilever distances exceed those specified in table 1 (in section 4.1.8 of this code). Formply, or other deck material, must be laid out progressively. Wherever possible, the direction of the leading edge should be perpendicular to the joists (or parallel to the bearers). Formply should be placed on the joists with the installer located behind the sheet as it is positioned whilst standing on the previously laid sheet or provided work platform. In the event of a person tripping or stumbling they should fall on the sheet and not off the leading edge. Cover or protect all penetrations left behind the leading edge. Covers must be securely fixed and clearly signed to indicate they are protecting a penetration (see section 4.1.9). Nail or otherwise secure formply to the joists as soon as practical. Only persons involved in the construction of the formwork should be located in the formwork construction zone (see Diagram 5). Any person not involved in construction of the formwork deck and support structure should be excluded.
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The leading edge should be free of oil, sawdust and obstructions to reduce the likelihood of slips and trips.
4.1.7 Cantilevers
Cantilevered bearers, joists and ply sheets can be hazardous when left unsecured. The weight of a person standing on the cantilever may make the timber see-saw and cause the person or material to fall. When designing the formwork system the use of cantilevers should be kept to a minimum. However, in some situations the use of cantilevered sections is unavoidable. Where this is the case, a formwork designer or engineer must consider the potential for persons and stored materials to cause cantilevers to pivot. Wherever the weight of a person will cause a cantilever to pivot, the cantilever must be positively secured such that this will not occur. Table 1 provides guidance on the maximum permissible cantilever length without securing the back of the cantilever. The information is based on a persons weight of 120 kg and includes a factor of two to allow for live loading when a person steps on to the cantilever: Member section size and material type 150 x 100 mm oregon bearer 150 x 100 mm oregon bearer 150 x 100 mm oregon bearer 150 x 77 mm LVL (laminated veneer lumber) bearer 150 x 77 mm LVL (laminated veneer lumber) bearer 150 x 77 mm LVL (laminated veneer lumber) bearer 100 x 75 mm oregon joist 100 x 75 mm oregon joist 100 x 75 mm oregon joist 100 x 75 mm oregon joist Total length of member 5m 4m 3m 5m 4m 3m 6m 5m 4m 3m Maximum cantilever without securing 420 mm 270 mm 150 mm 330 mm 220 mm 120 mm 310 mm 220 mm 140 mm 80 mm
Table 1 - Maximum unsecured cantilevers for structural members Where self-weight of timber is inadequate to ensure the stability of the cantilever, all cantilevers should be secured in accordance with the designers instructions. This may include nailing or another effective method such as bolting. Nailing should be carried out such that the nail will not pull out of the timber or shear off. Where skew nailing is used a minimum of two nails should be used and the nail should meet the designers specifications. Wherever practical, it is preferable to secure cantilevers such that the nail or bolt is loaded in pure shear (i.e. no pull-out load). The use of purpose designed brackets should also be considered. Materials should not be stacked or stored on a cantilever section unless written certification is provided by an engineer.
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4.1.8 Penetrations
Open penetrations, such as stairwells or penetrations to allow for services, create hazards for persons on the deck. A person may fall through a larger penetration, sustain injury by stepping into a smaller penetration or an object may fall through the opening onto persons below. Any penetration where there is a risk that a person or an object could fall through should be covered. Open penetrations must be protected either with edge protection (e.g. handrails) or securely covered. Cast-in metal mesh should be used for small diameter penetrations. The mesh should have a small aperture (e.g. 50 x 50 mm mesh size or smaller), and be made of material capable of withstanding the potential imposed load. Mesh provided over larger penetrations may require engineering certification to ensure it can withstand potential loads, including those applied by people, equipment and material. Where holes are cut in the mesh for services to pass through, the hole should be cut to the profile of the service so that mesh remains in the penetration. Ply covers on their own are not to be preferred because: the cover may be indistinguishable from other pieces of ply it may be difficult to determine if the ply is properly secured, and secured ply covers can be unsecured to gain access and not re-secured. However, where a ply cover is used in addition to cast-in mesh, it acts as a back-up system. Ply covers should be painted in a bright colour and be marked with the words Danger Hole Under. The cover should be firmly secured to the concrete and be designed for potential loads that may be applied. Before stripping formwork, ensure the penetration that will be exposed as the formwork is stripped is covered and or protected prior to the commencement of the stripping operation. Penetrations are also hazardous before the deck is laid. Joists placed up to the edge of the penetration should be secured so that the timbers cannot spread if a person falls on them.
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such as wind loading. This will generally only be an issue prior to placement of the deck on the modular system. To effectively control this issue the formwork system should be progressively braced in accordance with the suppliers instructions during its erection.
4.2.1 Training
Persons involved in the erection of modular formwork systems should be trained in the safe erection and dismantling of the system as well as inspection criteria for materials as an example, defects which would preclude the use of the materials. The modular system designer should provide written instructions on the erection and dismantling of the system and these instructions should at least provide equivalent levels of safety for a person as those detailed in this code. Training by representatives of the modular formwork system supplier is encouraged.
statement to ensure the concrete element will not fail and must have provided details on the structural engineering drawings as required by AS 3600 - Concrete structures. Documentation from the concrete supplier verifying the concrete specification should be available on request. A concrete sampling and testing procedure should be in place to verify concrete meets its design specification. Guidance on sampling and testing systems for concrete is provided in AS 1379 - Specification and supply of concrete. It is important to note that the compressive strength of laboratory cured test specimens may differ from the actual compressive strength due to factors such as temperature and humidity on site, poor curing techniques and the addition of water to the mix. Some builders may therefore choose to have test samples on site to give an indication of the variation between on site tests and laboratory tests.
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Basic items that ought to be checked include: The lifting gear is tagged and all relevant information listed (e.g. relevant information for a chain sling is grade of chain, safe working load, manufacturer, chain size and Australian Standard marking). Lifting hooks are provided with operable safety latches. Shackles are prevented from unscrewing (e.g. mousing or similar). Lifting eyes and inserts are compatible and the same proprietary brand. Lifting slings are not damaged (e.g. excessive wear, damaged strands, cracks, deformation and/or severe corrosion). The sling is appropriate for loads being lifted, including adequate capacity and protection from sharp edges. All lifting gear, including slings, hooks and material boxes, should be periodically inspected for damage and wear. The period between inspections shall depend on the severity of use but should not exceed 12 months. Documented maintenance records for the lifting gear should be available on site.
5.
Falling objects
The Work Health and Safety Regulation 2011 describes control measures that must be implemented to protect persons from falling objects. Falling objects are significant hazards, creating risks to workers and others during formwork erection, alteration and stripping, when slipping and jumping forms, and whenever loads are lifted over work areas. PCBUs have a duty to workers and other persons who could be injured or killed by any falling object during formwork activities.
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The control measures that are implemented should firstly aim to prevent objects from falling, but equally prevent injury if an object has fallen. Small objects, such as bolts and concrete aggregate, falling from a height can cause serious injury.
Diagram 6 - Height of perimeter screen in relation to building step in Persons not involved in formwork erection should not be located in the area of the building next to the step-in, unless controls have been implemented to prevent these persons being struck by falling objects.
5.3 Gaps
Gaps between perimeter screens and the formwork deck or floor should not be large enough to allow materials to fall below. This can be done by: fixed ply covers, or ply or rubber deflector shields that are connected to screens and the adjacent area cleaned up before they are moved.
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Deflector shields deflect objects onto the deck, preventing objects from falling further down the gap. They should be attached to the screens by a system that will ensure the shields do not fall when the screens are lifted and that is robust enough to withstand the environment. Deflector shields should be designed by an engineer and be adequate to resist impact loads likely to be applied (i.e. from bearers, formply props, etc.) Where chain is used to secure deflector shields, it should have a minimum link size of 5 mm and be corrosion resistant. Light gauge domestic type chain is not suitable as it is easily damaged and will rust. Covers should be designed for: potential loadings such as loads applied by workers the impact loadings of falling materials, and marking with their safe working load if they can be accessed as a platform.
6. Health concerns
6.1 Noise
The Work Health and Safety Regulation 2011 describes what must be done to prevent the risk to a person from exposure to excessive noise at work. Persons must be protected from the risk of noise induced hearing loss during their work. Activities, such as the erection or dismantling of formwork, the clanging and banging of metal on metal, or the use of hammers, create impact noise which can damage hearing immediately. This type of noise is particularly damaging to hearing because of its high impulsive noise levels. Other loud noise, such as that created when using a circular saw, will gradually damage a persons hearing after regular exposures. For formwork activities, often the only way to protect against noise induced hearing loss is by wearing appropriate hearing protectors whenever noise is produced. The selection of hearing protection is appropriate when the wearer can hear what goes on in the immediate environment. For most formwork activities a hearing protector with an SLC80 between 15 and 20, or a Class 2 or 3 rating, should be adequate, provided the hearing protector is worn correctly during noisy activities. Where a risk assessment shows the use of hearing protectors is the preferred option to control the risk of exposure to excessive noise, the use of the hearing protectors must be enforced when persons in the immediate vicinity are exposed to noise during various formwork activities.
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Reference should be made to the Queensland Managing Noise and Preventing Hearing Loss at Work Code of Practice for further information about managing noise exposure as a risk to workplace health and safety.
6.2 Dust
The Work Health and Safety Regulation 2011 details requirements for managing the workplace health and safety risk associated with hazardous chemicals. While concrete itself is not a hazardous chemical, high levels of silica dust can be produced during formwork processes. A hazardous chemical is generated when power tools cut, grind, chip, scrape, crush or blast materials such as concrete. Silica dust may be created to a lesser degree, by sweeping, cleaning, dismantling building equipment and demolition. Highly visible dust caused by earthmoving equipment on building sites or other earthworks sites is unlikely to contain hazardous levels of respirable silica dust. On the other hand, hazardous silica dust levels produced by other activities may be barely visible. Appropriate steps to minimise persons exposure to silica dust must be taken. Silica dust that is generated during formwork can be controlled by: using engineering controls such as dust extraction or a wet process, and providing respirators (as a last resort) where dust is likely to exceed permissible levels.
Store materials and equipment as close as practical to the work area and in a manner that facilitates ease of handling.
Provide mechanical aids Use mechanical aids such as cranes, hoists, pallet jacks and trolleys to move materials, tools and equipment around the site and when loading and unloading vehicles wherever possible. Administrative controls Administrative controls are achieved by modifying work practices, policies and procedures to reduce exposure to the risk of a musculoskeletal injury due to the performance of manual tasks. Administrative controls are less preferred as they only reduce exposure to the risk factors, they rely on ongoing supervision to ensure they are implemented, and they may be forgotten under stressful conditions (e.g. when trying to meet deadlines). Examples of administrative controls include: Work organisation Incorporate rest breaks or task variety into the job where the risk can not be prevented or minimised. Ensure adequate numbers of persons to meet deadlines. Task specific training Provide education and training in relation to the performance of manual tasks. This includes training in the correct use of mechanical devices, tools and equipment, as well as safe performance of the specific manual tasks and handling methods (e.g. team lifting). Team lifting is not a preferred method for load handling and should only be used as a last resort when mechanical aids cannot be used or the work cannot be redesigned. Persons must be trained in team lifting techniques and adequate numbers of workers must be provided. Preventative maintenance program Clean and maintain tools, equipment and formwork components regularly. When developing controls, it is critical to consider formwork as part of the overall construction process as each stage can have an impact on the level of musculoskeletal risk a person is exposed to. As such, controls should be implemented at all stages, from design and planning through to construction and all duty holders, including manufacturers and suppliers, should consider the manual tasks risks.
Lateral support can be provided to vertical elements in a variety of ways including horizontal and angled braces and structural connections to other parts of the building. A bracing element must be verified and signed off by an engineer. The bracing element must also be able to resist both tensile and compressive loads that may be applied by the wind. Anchors for braces should preferably be cast-in type anchors or through-bolts that extend through both sides of the anchoring medium. Drill-in anchors of the following type may be used provided they are installed in accordance with the manufacturers instructions: Undercut type anchor that do not rely on friction to function. Expansion anchors of the high-load slip, torque controlled type. These anchors have a working load of at least 60 per cent of the first slip load and are generally suitable for structural tensile loads. Coil bolts. The correct operation of coil bolts is greatly dependant on their being installed in accordance with a manufacturers specifications (e.g. drilling the correct size hole and applying the correct torque in concrete of adequate strength). Drill-in type anchors should have their torque set using an appropriate torque wrench or another reliable method that will verify the torque (i.e. a calibrated rattle gun). Written records verifying the setting torque for all drill-in type anchors should be available on site.
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A trailing stair system is preferable to a ladder system because it is easier for persons to ascend and descend and emergency evacuation is generally easier on a stair system. The access area between the trailing access system and the building should be clear of trip hazards and there should be no gaps between platforms exceeding 100 mm wide. A designer of formwork should ensure the trailing access system is designed for loads that could be applied in an emergency evacuation situation. Both the strength of the system itself, and the ability of the form to withstand applied loads from the access system, should be adequate. The trailing stair access system should be designed for a load of at least 2.5 kPa unless the designer is able to justify a lesser load based on the anticipated number of persons on the form at any one time. Where the designer of the formwork specifies a lesser live load than 2.5 kPa, the following should be ensured: A sign stating the maximum load that can be applied to the stairs should be fixed to the stairs in a visible position. Written procedures are implemented to ensure the total acceptable number of persons on the form is not exceeded. Ladders should be secured in place and should be placed at an angle between 70 and 80 degrees to the horizontal, where this is practical. Access openings for ladders on working decks should be provided with trapdoors that are closed except when being accessed. Trapdoors should be provided with a device so that they can be easily opened from above. This device should not pose a trip hazard for persons on the deck. Access ways should be kept free of materials and rubbish to prevent objects falling to the level(s) below.
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When removing a form from a vertical element, the form must be effectively supported such that it never relies on suction for support. Serious incidents have occurred when it has been assumed that a form is supported from above when it is in fact relying on through bolts through the wall for support. When the bolts have been removed the form has fallen, with the persons still standing on a platform attached to the form. This hazard can apply both to crane lifted forms and jump forms.
8.5 Training
In view of the specialised work systems and unique hazards that exist on jump forms and slip forms, specific training should be provided for persons intending to work on the forms. Training should include, but not be limited to: The maximum loadings that can be applied to the various areas on the form. This would include information about areas where materials can be stored. Restricted access areas and procedures for installation and removal of edge protection. Climbing or jumping procedures for those involved in these operations. Emergency evacuation procedures for those required to work on the form. Fire fighting procedures to be used in emergency situations prior to fire fighting personnel arriving at the scene. Any other special work procedures that specifically apply to working on the form. As examples, time limits for working in cells where these apply or safe undertaking of manual tasks.
Section 2 of this code discusses engineering issues. In addition, the following factors must be addressed by the designer of these types of formwork: Minimum concrete strength required prior to climbing. Allowance for all loads, including dynamic and wind loads that may be applied to the form. Loads applied by workers and concrete placing activities must also be allowed for. Allowance may also need to be made for impact loading when materials are lifted onto the deck of the form. The designer must consider the effects of eccentric loading on the form, both during climbing and at other times, and note the requirements in the operating procedures for the form. The maximum degree to which the form can be out-of-level during climbing, and the procedure required both to minimise the likelihood of this occurring and how to remedy the situation if the form becomes out-of-level. Consideration of rescue procedures that may affect the design of the form. The rescue procedure may require access to all levels of the form and cells, either through the provision of gates or removal of panels on the form.
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Appendix 1: Dictionary
Bearer: Primary horizontal support members for a formwork deck that are placed on top of formwork frames. Bearers are usually constructed from timber but are sometimes constructed from metal, such as in the case of some modular formwork systems. An area of a slip form, jump form or crane lifted form where a worker or workers are required to carry out work. The cell will at least be enclosed by all sides and a bottom surface. In relation to performing an inspection or other task for a control measure is a person who has acquired, through training, qualifications or experience the knowledge and skills to do the work in a safe way, including: sound knowledge of relevant Australian Standards, relevant codes of practice and other relevant legislation, and sound knowledge of, and competence in, the risk management process for the erecting, altering and dismantling of formwork, including: - hazard identification and risk assessment - measures to control exposure to risks - safe work practices and procedures, and - how to plan and prepare formwork. A protective structure fixed to the perimeter of the building, structure or working platform to contain objects and prevent them from falling. A barrier to prevent a person falling erected along the edge of: A building or other structure. An opening in a surface of a building or other structure. A raised platform. In relation to the performance of a task, means a person who: is a registered professional engineer under the Professional Engineers Act 2002, and is competent to perform the task. A deck provided to safely arrest a falling person and/or provided as a working platform (different to the pouring deck). An object used in the casting of concrete walls or columns that has part of its surface in contact with the concrete during the concrete curing process. A person who is competent in designing formwork and who holds a relevant degree in engineering or building or has successfully completed courses in formwork design and has appropriate experience in this field.
Cell:
Competent person:
Containment sheeting:
Edge protection:
Engineer:
False deck:
Form:
Formwork designer:
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Formwork frame:
A structural assembly, a number of which are used to support a formwork deck. Bearers are placed directly on these frames. Any horizontal member of a formwork or scaffold frame that is provided as stiffening for the frame and may also be used to support a working platform (included the term transom in reference to scaffolding). A platform at least two planks wide, located less than 2 metres above a continuous deck. Secondary horizontal support members for the formwork deck that are placed on top of bearers, at right angles to the bearers. Joists are usually constructed from timber but are sometimes constructed from metal, such as in the case of some modular formwork systems. A class of high risk work endorsed on a licence to perform a class of high risk work.
Horizontal member:
Intermediate platform:
Joist:
Licence class:
A formwork system that is specifically designed for formwork and consists of components that are not designed to be used with other systems.
Edge protection that is provided on the perimeter of the formwork to be erected. (n.b. Perimeter edge protection will prevent a fall off the outside perimeter of the formwork but will not prevent internal falls through the formwork). A deck on which concrete is poured. A slender structural member placed in a vertical position between two horizontal surfaces and used to support the upper surface. The proprietary term Acrow is often used to describe the prop. The height of a prop is usually adjustable. A vertical structural member which may or may not form part of a frame, also known as standard, vertical tube.
Vertical member:
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Specifications
Yours faithfully
RPEQ No.
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Dear Mr .. Project . I certified that the variations to the formwork system detailed below have been checked and satisfy the Australian Standards AS3610 Formwork for Concrete and AS3600 Concrete Structure and the Project documentation including the structural engineering drawings and specification. Variation number Details of variation of formwork system
Yours faithfully
RPEQ No.
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Water-tightness Are all joints properly sealed and cramped? Are the construction joints sealed? Concrete/concreting What is the maximum rate of placement permitted? Are the forms maintaining line, level, plumb, shape, etc during concreting? Stripping What are the minimum stripping times? Has the project designer permitted modification of these? Do the procedures enable stripping without damage to form or concrete? Are the provisions consistent with the re-use times required? Has the crane the necessary slings, etc to move the forms quickly? What curing methods must be used once the formwork is removed? Is the storage area for the formwork organised? Safety Are there adequate guardrails, handrails, walkways, signs, etc in position?
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This is to certify that the .. Formwork for the above project has been inspected and is considered to be adequate to support the design loads in accordance with the Queensland code of practice for Formwork and relevant AS codes including AS 3610 Formwork of Concrete. The following items were included in the inspection: ITEM Base Plates Frame spacing Frame bracing Frame extensions Bearer size and spacing Joist size and spacing Prop spacing Prop bracing Eccentric loading Prop inclination Timber condition Steel condition Nails in plates as reqd Column framing Column bracing Plywood fixing CONDITION OK OK OK OK OK OK OK OK OK OK OK OK OK OK OK OK WORK REQD Yes/No?? No No No No No No No No No No No No No No No No Signature
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