Formwork Code of Practice 2006

Important information about the Formwork Code of Practice 2006

1. The code was made on 2 August 2005.

2. The code commenced on 1 January 2006.
3. The code was amended on 28 April 2006
4. The code expires 10 years after it commenced.

What is this Code of Practice about?

The purpose of the Formwork Code of Practice 2006 is to give practical advice about
ways to manage exposure to risks associated with work involving the erection,
alteration and/or dismantling of formwork.

Workplace health and safety obligations and the Workplace Health

and Safety Act 1995
The Workplace Health and Safety Act 1995 imposes obligations on certain persons
to ensure workplace health and safety. Workplace health and safety is ensured
when persons are free from death, injury or illness (and the risk of death, injury or
illness) created by workplaces, relevant workplace areas, work activities, or plant or
substances used at a workplace. Ensuring workplace health and safety involves
identifying and managing exposure to risks at your workplace.

How can l meet my obligations?

Under the Act, there are three types of instruments to help you meet workplace
health and safety obligations – regulations, ministerial notices and codes of practice.

If there is a regulation or ministerial notice about a risk, you MUST do what the
regulation or notice says.

If there is a code of practice about a risk, you MUST either –

(a) do what the code says; or
(b) do all of the following –
- adopt and follow another way that gives the same level of protection against
the risk;
- take reasonable precautions; and
- exercise proper diligence.

If there is no regulation, ministerial notice or code of practice about a risk, you must
choose an appropriate way to manage exposure to the risk and take reasonable
precautions and exercise proper diligence to ensure that your obligations are met.
Note:
There may be additional risks at your workplace that have not been specifically addressed in this Code
of Practice. You are still required under the Workplace Health and Safety Act 1995 to identify and

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assess these risks and ensure that control measures are implemented and reviewed to eliminate or
minimise exposure to these risks.

The Risk Management Code of Practice provides a process to help you meet your workplace health
and safety obligation by identifying and managing exposure to the risks at your workplace.

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 TABLE OF CONTENTS
1. INTRODUCTION................................................................................................... 3
1.1 FALLS FROM HEIGHTS ..................................................................................... 4
1.1.1 Unsuitability of harness systems for formwork activity...................................................... 4

2. DESIGN ................................................................................................................ 6
2.1 SAFE DESIGN OF BUILDINGS IN RELATION TO FORMWORK ................................... 6
2.1.1 Buildability ......................................................................................................................... 6
2.1.2 Materials ............................................................................................................................ 7
2.2 FORMWORK SYSTEMS ..................................................................................... 8
2.2.1 Safe formwork design and verification .............................................................................. 8
2.2.2 Formwork design certification requirements ..................................................................... 9
2.2.4 Design variations............................................................................................................. 12
2.2.5 On site coordination and verification ............................................................................... 13

3 COORDINATION AND ADMINISTRATION ......................................................... 15

3.1 WORK PROGRAM .......................................................................................... 15
3.2 HOUSEKEEPING ............................................................................................ 15
3.2.1 Access ............................................................................................................................. 15
3.2.2 Material storage...............................................................................................................15
3.2.3 Rubbish storage and removal ......................................................................................... 16
3.3 TRAINING ..................................................................................................... 16

4. WORK SYSTEMS............................................................................................... 18
4.1 FORMWORK ERECTION – TRADITIONAL SYSTEMS ............................................. 18
4.1.1 Foundations..................................................................................................................... 19
4.1.2 False deck ....................................................................................................................... 19
4.1.3 Erecting frames ............................................................................................................... 20
4.1.4 Installing bearers .............................................................................................................21
4.1.5 Installing joists ................................................................................................................. 22
4.1.6 Fall protection from the formwork deck ........................................................................... 22
4.1.7 Laying formply on the deck ............................................................................................. 23
4.1.8 Cantilevers....................................................................................................................... 25
4.1.9 Penetrations .................................................................................................................... 26
4.1.10 Working areas for steel fixers and others ................................................................... 27
4.1.11 Changing floor levels .................................................................................................. 28
4.2 FORMWORK ERECTION – MODULAR FORMWORK SYSTEMS ................................ 28
4.2.1 Training............................................................................................................................ 29
4.3 STRIPPING FORMWORK ................................................................................. 29
4.3.1 Work method statement .................................................................................................. 29
4.3.2 Bond reduction ................................................................................................................ 30
4.3.3 Certification prior to stripping........................................................................................... 30
4.3.4 Exclusion zone ................................................................................................................ 30
4.3.5 Drop stripping .................................................................................................................. 31
4.4 CRANE AND LOAD HANDLING SYSTEMS ........................................................... 31
4.4.1 Loading materials during formwork construction............................................................. 31
4.4.2 Access for persons slinging loads ................................................................................... 32
4.4.3 Lifting gear....................................................................................................................... 33
4.4.4 Lifting formwork materials ............................................................................................... 33
4.4.5 Lifting lugs ....................................................................................................................... 34

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 4.5 USE OF LADDERS.......................................................................................... 34

5. FALLING OBJECTS........................................................................................... 36
5.1 PREVENT THE OBJECT FROM FALLING. ............................................................ 36
5.1.1 Perimeter containment screening.................................................................................... 37
5.2 BUILDING STEP-INS ....................................................................................... 37
5.3 GAPS .......................................................................................................... 38
5.4 PRIOR TO LIFTING ......................................................................................... 39

6 HEALTH CONCERNS ...................................................................................... 40

6.1 NOISE ......................................................................................................... 40
6.2 DUST........................................................................................................... 40
6.3 MANUAL TASKS ............................................................................................ 41
6.3.1 Control measures for manual tasks ................................................................................ 41

7. SPECIAL REQUIREMENTS FOR WALL AND COLUMN FORMS.................... 43

7.1 BRACING FOR WIND LOADING ......................................................................... 43
7.2 ACCESS PLATFORMS..................................................................................... 43
7.3 LIFTING METHODS ......................................................................................... 44

8. SPECIAL REQUIREMENTS FOR SLIP FORMS AND JUMP FORMS .............. 45

8.1 ACCESS AND EGRESS ................................................................................... 46
8.2 WORKING PLATFORMS AND PENETRATIONS ..................................................... 47
8.3 TRAILING SCREENS AND PLATFORMS .............................................................. 47
8.4 CLIMBING THE FORM ..................................................................................... 48
8.5 TRAINING ..................................................................................................... 49
8.6 HEALTH ISSUES AND AMENITIES ..................................................................... 49
8.7 ENGINEERING ISSUES ................................................................................... 50
8.8 EMERGENCY ISSUES ..................................................................................... 50

APPENDICES .......................................................................................................... 52

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1. Introduction
Formwork is the surface, supports and framing used to define the shape of concrete
until the concrete is self-supporting: (see AS3610 Formwork for Concrete).

‘Formwork’ includes:
• the forms on which concrete is poured;
• the supports to withstand the loads imposed by the forms and concrete; and
• any bracing added to ensure stability.

Together these components make the formwork assembly.

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; and
• assess risks that may result because of the hazards; and
• decide on control measures to prevent, or minimise the level of, the risks; and
• 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.

Where this is not Where this is not practical,

practical, prevent a fall arrest a fall and prevent or As a last resort and/or
Design and planning For example, through the minimise injury from the to complement higher
Eliminate the risk during use of edge protection, a arrested fall order control measures
the design and planning cover placed over an For example, through the use implement
stage. opening. of a fall arresting platform. administrative
controls.

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1.1 FALLS FROM HEIGHTS

The Workplace Health and Safety Regulation 1997 describes what must be done
where there is a risk that a person could fall.

Controls to prevent or minimize the risk of death or injury from falling must be
implemented before the commencement of construction work.

Because of the significant risk of death and serious injury from working at heights
Queensland legislation requires that fall protection be provided for persons working
at 2 metres for construction work (other than when working on housing construction
where the limit is 3metres). Below these threshold heights, Queensland legislation
requires that a risk assessment must be applied.

1.1.1 Unsuitability of harness systems for formwork activity

The use of:

• travel restraint harness systems to prevent a fall; or

• fall arrest harness systems to arrest a fall

when erecting, altering and/or dismantling formwork are not recommended because:

Travel restraint harness systems

• Travel restraint systems, as a means to prevent a person falling, are impractical

for formwork because:
• The contour of the leading edge is constantly changing so that the length of
the travel restraint line needs to be continually adjusted; and
• Multiple lanyard anchorage points may be required; and
• The greater the number of workers building the formwork deck, the greater
the likelihood of lines becoming tangled.

Fall arrest systems

• The Workplace Health and Safety Regulation 1997 prohibits the use of fall arrest
systems where there is insufficient distance available to prevent a person hitting
an object, the ground or another surface, other than a vertical surface; and

• When erecting, altering and/or dismantling formwork there will be inadequate free
fall distance underneath the working area and a person will strike the ground, a
frame or other obstruction prior to the fall being arrested; and

• A falling person can require in excess of 6 metres free fall distance for the fall to
be safely arrested by a harness system. In some situations this distance can be
substantially reduced by the use of shorter lanyards and/or higher anchorage
points; and

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• The design loads required for fall arrest systems are relatively high. The
Workplace Health and Safety Regulation 1997 specifies that each anchorage
point of the system must have a capacity of 15 kN for one person free-falling; and

• The erection of formwork frames using fall arrest harnesses requires the user to
regularly connect and reconnect to anchorage points. This requires use of a
double lanyard.

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2. DESIGN

The Workplace Health and Safety Act 1995 provides that the designers of structures
to be used as workplaces have obligations for workplace health and safety.

2.1 SAFE DESIGN OF BUILDINGS IN RELATION TO FORMWORK

2.1.1 Buildability

The designers of buildings, including engineers and architects, must consider the
‘buildability’ of a structure or building and produce a design that minimises the risk of
injury during construction.

The design of the final concrete structure can have a major effect on the ease of
formwork construction, and consequently, on the safety of persons during
construction. Generally, the more basic and simple the final concrete structure, the
safer it is to erect.

A designer of formwork should be consulted during the design of any building to

provide input on ways to minimise the risk of injury.

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 don’t 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 handling 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

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varying depth introduce a greater quantity of cantilevered beams and joists, which
contribute to the risk of a person falling.

Diagram 1 - Flat floor and deep floor beams

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).

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2.2 FORMWORK SYSTEMS
The design of all formwork systems must satisfy:
• AS3610 - Formwork for Concrete; and
• AS3600 - Concrete Structures.

2.2.1 Safe formwork design and verification

A designer of formwork, either a ‘formwork designer’ or a ‘professional engineer’, is

responsible for overseeing the safe design of the complete formwork structure. This
includes design of the formwork support structure, the formwork deck and
connection details.

‘Formwork Designer’ and ‘Professional Engineer’ are defined in the dictionary at

appendix 1.

When specifying the design of the formwork system, a designer of formwork must
allow for all loads that can be expected to be applied during construction, including
loads applied by:
• the formwork deck, supporting members and formwork frames;
• any false decks that may be provided;
• concrete pouring techniques (i.e. kibble or pump);
• the concrete pour which includes both the weight of the concrete and dynamic
factors applied. The concrete pour rate and pour sequence must be specified;
• workers on the formwork deck and false decks;
• stacked materials;
• crane lifted materials on both the complete and incomplete formwork deck;
• wind to the system as detailed in AS 1170.2 Structural Design Actions - Wind
Actions. An allowance for wind loading is particularly important for vertical forms;
and
• environmental loads including forces due to water flowing around the formwork.
Rain and run off can have a detrimental effect if not considered by a designer.

Wind loading

A designer of formwork must consider wind loadings on formwork, particularly for

external walls, columns, free-standing shutters, blade walls and any platforms which
may be subject to uplift.

Vertical elements must be fully braced prior to and during stripping, and until such
time as the construction will provide adequate support and/or protection against wind
loading.

Wind loading will vary depending on:

• the size of form;
• the nature of the form;
• wind speed;
• wind resistance (e.g. screens); and
• wind direction.

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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); and
• 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.

2.2.2 Formwork design certification requirements

This Code of Practice, divides formwork into two types:

• ‘basic formwork systems’ ; and
• ‘non–basic formwork systems’.

A formwork designer may certify a ‘basic formwork system’. Only a professional

engineer may certify a ‘non-basic formwork system’.

While this Code requires that certification for non-basic formwork systems may only
be performed by a professional engineer, it is recognised that the majority of any
such design work may be performed by appropriate personnel experienced in
formwork design and documentation, such as a formwork designer.

For basic formwork systems and non-basic formwork systems, certification must
confirm that the formwork drawings, other formwork documentation, and the project
documentation (as detailed in sections 2.2.3 of this Code) have been completed as
required for the project. Sample engineer’s certification letters are provided at
appendix 2.

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Basic formwork systems

A formwork designer or professional engineer may provide certification of a ‘basic

formwork system’.

For the purposes of this Code, a basic formwork system is understood as the
formwork for a floor, wall or column.

A basic formwork system includes:

• 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; and
• 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 a professional 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 a professional 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;

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• 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;
• 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;
• 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;
• professional 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;

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• 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, waterstops, 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.

2.2.4 Design variations

All variations from the design of a formwork system must be checked by a formwork
designer (for a basic system) or a professional engineer (for a non-basic system)
and:
• certified in writing by a formwork designer or professional engineer as being
acceptable (that is, complying with AS 3610 Formwork for Concrete), if the
formwork designer or professional engineer can verify this is the case; or
• altered in accordance with the written directions of a formwork designer or
professional engineer in order to comply with AS 3610, within a time frame
specified by the formwork designer or professional 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 a professional engineer; or
• connections between traditional formwork and modular formwork.

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2.2.5 On site coordination and verification

The following documentation must be available for inspection on site:

• certification of the maximum loads from stacked materials that the formwork
assembly can withstand;
• specifications for the concrete and when formwork can be removed;
• backpropping details (plans and elevations including tying in); and
• drawings for the formwork design. The drawings must be signed by a
professional engineer or formwork designer or be accompanied by a certification
letter that lists the drawing numbers and drawing revision numbers.

A suitable system must be implemented to ensure that only materials and

components that comply with the specifications of the formwork design drawings and
documentation are being used. Materials and components that are damaged or
excessively worn must not be used.

Verification of the structure with the design

Verification that the formwork structure complies with the design of the formwork
system must be documented and provided. A construction check list (as illustrated
at appendix 3) can be used to assist in this process. Relying solely upon such a
checklist will not be sufficient to verify compliance with relevant Australian
Standards.

The verification and documentation that a design has been complied with may be
delegated to a ‘competent person’ on site (see appendix 1 for the definition of
“competent person”).

A competent person, if not a professional engineer or formwork designer, must have

appropriate training and knowledge to perform onsite inspections of the formwork
system. This delegated person needs to be experienced in formwork construction
and be competent in reading drawings and be able to certify that the formwork
structure satisfies the details on the formwork drawings, specifications and any other
formwork documentation.

Should the competent person on-site not be a formwork designer or a professional

engineer, the delegated person can only verify that the designer’s specifications and
drawings have been complied with. A competent person who is not a formwork
designer or professional engineer must not authorise variations to the design. The
delegated person may require corrections to the formwork system if some details do
not pass as indicated on the construction checklist by providing written instructions
on remedial action to be undertaken prior to the concrete pour.

If any items on the construction checklist are to be referred to a professional

engineer, then the competent person must refer them to a professional engineer in
writing. A competent person must ensure the remedial action has occurred prior to
the concrete pour including any items referred to a professional engineer for
certification and modified as instructed by a professional engineer.

A pre-pour inspection ought to focus on such matters as:

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• 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 pre-pour 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 a professional engineer, formwork designer or competent person is

required following the final pre-pour 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.

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3 Coordination and administration
3.1 WORK PROGRAM
The risk to a person’s health and safety must be considered when designing a work
program for erecting, altering and/or dismantling formwork. At the very least
consideration must be given to:
• sequencing work to ensure sufficient time is allowed for each work activity;
• coordinating trades to allow work to be completed free from obstruction;
• allowing for the progressive clean up of work areas to prevent rubbish becoming
a trip hazard and allowing access for mechanical aids; and
• taking account of edge protection requirements and ensuring these are designed
and constructed appropriately.

3.2 HOUSEKEEPING

The Workplace Health and Safety Regulation 1997 places obligations 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 Workplace Health and Safety Regulation 1997 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 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.

3.2.2 Material storage

The Workplace Health and Safety Regulation 1997 requires that there are safe
storage areas for material and plant.

Materials must be stored so as to minimise manual tasks hazards, trip hazards and
the potential for falling objects. Smaller components such as U-heads, couplers,
base plates and ’Z-bars’ should be contained in material boxes. Where practicable,
frames and formply should be strapped until it is time to use them. Bearers and
joists should also be strapped together in bundles or stacks. These bundles or

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stacks should be located back from the edge of the deck or openings to prevent
materials or persons accessing the materials falling through or off the deck.

It is preferable to lay wall forms flat on the ground instead of leaning them against
structures or other forms that are not purpose made “A” frames. Timbers, or another
effective means, must be provided under the forms where slings are to be placed
under the forms for crane lifting.

When not in use, wall forms may be stacked in or against purpose made “A” frames.
This is preferable to leaning the forms against other structures. If this is not
practical, wall forms must be stacked in such a way that they cannot move away or
rotate from the surface they are placed against. A professional engineer must verify
in writing that a surface to be used for the stacking of forms is capable of
withstanding the impact of all imposed loads, including wind loading.

Incorrect materials delivery and storage can create significant manual handling
tasks. Safe work practices to minimize exposure to these risks include:

• ensuring the formwork materials are delivered as close as possible to the job;
• designing and designating a small section of the formwork as a loading platform
to load ply and other components;
• ensuring mechanical aids are used to handle loads wherever possible;
• storing loads on trolleys to minimize double handling or on raised platforms to
minimize manual lifting from ground level; and
• having adequate storage space or lay down area to safely store materials and
equipment and to minimize double handling.

3.2.3 Rubbish storage and removal

The Workplace Health and Safety Regulation 1997 requires that there be a safe
system for collecting, storing and disposing of excess waste materials at the
workplace.

Rubbish storage and removal for formwork may include the provision of rubbish
skips and wheel barrows that are moved as work progresses. However, rubbish
skips should only be positioned where the supporting structure has adequate
strength to support the total weight of the bin and likely contents.

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;

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• 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(es).

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;
• Queensland’s workplace health and safety legislation, including relevant parts of
this Code of Practice;
• the workplace’s health and safety policies, and relevant procedures and 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.

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4. WORK SYSTEMS
4.1 FORMWORK ERECTION – TRADITIONAL SYSTEMS

The Workplace Health and Safety Regulation 1997 describes what must be done
where there is a risk a person could fall.

The Workplace Health and Safety Regulation 1997 requires the preparation of a
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 stabilize 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.

Diagram 2 - Worker erecting formwork on two planks

Under the Workplace Health and Safety Regulation 1997, a person is not permitted
to work where they are at risk of falling 2 metres or more unless suitable control
measures are in place. These measures must be in place prior to the
commencement of the formwork activity.

Even when the potential fall distance is less than 2 metres, 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.

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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 a professional 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 a professional 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 professional engineer or formwork designer.

4.1.2 False deck

In situations where a deck is at a height that would require persons to stand at

heights of 2 metres or more to install bearers and joists for the formwork deck, a
continuous “false” deck , which is, a full deck the same area as the floor being
formed, should be provided (see diagram 3). This deck should be provided both
inside and between formwork frames and can typically consist of formply, scaffold
planks or modular platform sections. A protected access opening can be left in the
deck to enable materials to be lifted up. The use of a captive platform system is
preferable to lapped planks because a captive system cannot be accidentally
dislodged. Lapped planks may only be used if secured against uplift and slipping.
The false deck must be constructed such that no gap exceeds 225 mm width and
gaps may only exist where a vertical member of a frame passes through the deck.

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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.); and
• a uniformly distributed load of 2 kPa which is equivalent to a mass of 200kg per
square meter.

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.

4.1.3 Erecting frames

Persons erecting formwork frames must be trained in their safe erection. One
means of demonstrating that a person is competent to do so is their holding
certificates to erect scaffolding (as a ‘prescribed occupation’: see appendix 1) or are
scaffolding trainees and have experience in formwork erection.

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The Workplace Health and Safety Regulation 1997 provides the requirements for
training and responsibilities of employers and persons performing prescribed
occupations.

Under the Workplace Health and Safety Regulation 1997, a person must hold a
certificate if a person or thing may fall more than four metres from the scaffold.
Trainees are permitted to perform scaffold work, provided the trainee is adequately
supervised by a ticketed person who is on site, and a written record outlining the
training received (such as a log book) is maintained.

Formwork frames must be erected in a progressive manner to ensure both the

installers safety and the stability of the overall structure. Braces must be attached to
the frames as soon as practical.

The risk of a fall can exist on edges of formwork frames during their erection. In this
situation, it is necessary to install edge protection on the frames as they are erected.
Provided the side bracing (or 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. This is consistent with the requirement
for the erection of edge protection on scaffolding specified in the Workplace Health
and Safety Regulation 1997. 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.

4.1.4 Installing bearers

Bearers must be placed in position so that persons are located no more than 2
metres from the floor or from the fall arresting platform located immediately below
them. For example, the bearer can be lifted up onto the top of the formwork frame
with a person standing on a platform erected no more than 2 metres from the floor or
false deck located immediately below them within the frame.

Bearers must be positioned such that they will not fall off the top of the frames. The
usual method of ensuring this is by placing the bearers in U-heads on top of the
frames and by ensuring cantilevers are minimized. Where only single bearers are
placed in the U-head, the bearer must be placed centrally in the U-head unless a
formwork designer or professional engineer states otherwise. Where the top of the
supporting member consists of a flat plate, the bearer must be nailed or otherwise
effectively secured to the plate. Flat plates may only be used where specified by a
formwork designer or professional engineer.

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4.1.5 Installing joists

Where a false deck is provided at 2 metres or less below a worker, joists may be
spread on the bearers with the worker standing at bearer level (that is, on top). If the
height of the deck being constructed is more than 2 metres above a continuous deck
or surface below it, joists must be spread from a platform located within 2 metres of
that surface, underneath the deck being constructed.

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

The joists are lifted by the workers from underneath and spread on top of the
bearers into their approximate final positions whilst standing on a lower work
platform. The platform below the deck should be positioned at a height
appropriate for handling joists (without introducing manual tasks risks) and not
greater than 2 metres.

4.1.6 Fall protection from the formwork deck

During formwork construction the structure is constantly changing. Hence, continual

modification of fall protection measures is also necessary. One of the biggest
challenges is to provide adequate fall protection on the leading edge of the formwork
deck. Where there is only one leading edge (i.e. the other edges are provided with
scaffolding edge protection), the provision of fall protection on the leading edge is
relatively straightforward. However, where there are multiple leading edges and/or
the deck is not at one consistent level the provision of fall protection can be very
difficult to implement. Designers of buildings are therefore encouraged to design
floor slabs that are one consistent thickness.

Leading edge and perimeter protection must be provided on edges where the
potential fall distance is 2 metres or more and a person is not prevented from being
within 1800 mm of the edge. Control measures are required where a person could
fall onto an object, such as frames, reinforcing steel or a rubbish skip.

Edge protection on the formwork deck

The Workplace Health and Safety Regulation 1997 provides the requirements for
edge protection which may be used as a control measure to prevent the risk of death
or injury from a fall during construction work.

All edge protection used for formwork must comply with the requirements for edge
protection detailed in the Workplace Health and Safety Regulation 1997.

Where the design of the formwork is complex, it may be impractical to provide edge
protection on leading edges because the profile of the deck is constantly changing
and construction of leading edge protection would create more hazards than it would
control. For example, the persons installing the edge protection could be exposed to
risk when installing the edge protection. However, in some situations it may be
necessary to provide perimeter edge protection on edges of the formwork deck.
Examples where edge protection must be installed are:

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• There is a change in deck height along the side of the deck being constructed
(i.e. a drop down for a beam) and no joists and/or formply has been provided at
this different height; and
• If a leading edge is to be left unattended and access onto the deck by persons
other than formworkers is required (i.e. the formwork deck has not been
barricaded off and provided with “keep out” signs).

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 4 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.

4.1.7 Laying formply on the deck

A formwork deck must be laid in a progressive way such that persons will be
provided with a method of preventing them from falling below the deck. This control
measure is particularly important in situations where a false deck has not been
provided within 2 metres below the level of the deck to be laid.

Where a false deck has not been provided within 2 metres formply may only be
spread on the joists provided where:

• Persons commence laying the formply sheets from the perimeter scaffolding or
other edge protection that has been provided on the perimeter of the formwork;
and

• A minimum of four joists at 450 mm centers (400 mm gaps, totaling 1.8 metres)
are located on bearers next to the person and in the other direction joists extend
for at least 1.8 metres (see diagram 4). Therefore, if a person falls they will fall

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 onto the joists and should be prevented from falling further. (Note, in some
situations, there may be a possibility of a person falling through the joists if the
joists spread as the person’s body makes contact. This is more likely to be a
potential hazard when the person falls onto the joists such that the person’s fall is
in the same direction as the joists. Implementing controls to minimise sideways
movement of joists will minimise this possibility); and

• Persons lay the formply in front of their bodies so that if they stumble they are
likely to fall on top of the sheets being laid.

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 2
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; and

• 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 millimetre

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 centres (maximum) or so that the gap between joists does not exceed 400
millimetres; and

• 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); and

• 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); and

• 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; and

• 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); and

• Nail or otherwise secure formply to the joists as soon as practical; and

• If timbers have not been spread on the sides of the leading edge, edge protection
complying with the Workplace Health and Safety Regulation 1997 must be
erected; and

• 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; and

• The leading edge should be free of oil, sawdust and obstructions to reduce the
likelihood of slips and trips.

4.1.8 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
professional 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 person’s weight of
120 kilogram and includes a factor of two to allow for live loading when a person
steps on to the cantilever:

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 Member section size and Total length of Maximum cantilever
material type member without securing
150 x 100 mm oregon bearer 5m 420 mm

150 x 100 mm oregon bearer 4m 270 mm

150 x 100 mm oregon bearer 3m 150 mm

150 x 77 mm LVL (laminated 5m 330 mm

veneer lumber) bearer
150 x 77 mm LVL (laminated 4m 220 mm
veneer lumber) bearer
150 x 77 mm LVL (laminated 3m 120 mm
veneer lumber) bearer
100 x 75 mm oregon joist 6m 310 mm

100 x 75 mm oregon joist 5m 220 mm

100 x 75 mm oregon joist 4m 140 mm

100 x 75 mm oregon joist 3m 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 designer’s 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
designer’s 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 a professional engineer.

4.1.9 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.

Handrail requirements are detailed with the edge protection requirements of the
Workplace Health and Safety Regulation 1997.

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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.

4.1.10 Working areas for steel fixers and others

Steel fixers, plumbers and electricians, often follow closely behind the formwork
erection. The formwork zone must be sufficiently large to ensure that these other
persons are clearly separated from formworkers. A ‘formwork only’ zone should be
maintained behind the leading edge. This zone should be clearly demarcated by
signage and flagging. Diagram 5 illustrates the ‘other work’ zone, the formwork zone
and the area retained as edge protection (4 joists spaced 1800millmetres beyond the
laid deck).

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 Diagram 5 – End view of deck showing working zones

4.1.11 Changing floor levels

Formwork decks are rarely flat across the entire floor, generally due to deep beams
or ’drop downs’ (sometimes called ’capitals’) around columns. Uneven floors
introduce fall hazards. It is preferable that these hazards be eliminated at the design
stage (see section 2). These hazards are most effectively managed by ensuring that
formwork supports and the deck are progressively constructed for the lower parts of
the deck before work commences on the higher-level areas of the deck.

4.2 FORMWORK ERECTION – MODULAR FORMWORK SYSTEMS

The basic principles discussed in section 4.1 on traditional systems should be
applied to the erection of modular formwork systems. Although the erection
technique and member dimensions may vary greatly between traditional systems
and modular systems, the principles of maximum potential fall distance and gap
width at the working level should be applied. The width of any gap on a working
level is not to exceed 400 mm unless a false deck has been provided within 2 metres
of the working level. Working platforms used for modular systems should also have
a minimum width of 450 mm.

Modular and traditional formwork systems should be designed to comply with the
loadings and general principles of AS 3610: Formwork for concrete.

Traditional formwork systems are sometimes used next to and connected to modular
systems, particularly around unusually shaped areas. Where this is the case, the
formwork drawings should show this and should be certified by a professional
engineer or formwork designer. However, components from other types of formwork
systems should not be used as an integral part of the modular formwork system
unless the designer of the modular system states in writing that this is permitted.

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Modular formwork systems are often lighter weight and require less physical effort
than traditional systems because they are often constructed from aluminium instead
of steel and they eliminate the need for tasks such as repetitive hammering. This
reduces a person’s exposure to the risk of injury resulting from undertaking manual
tasks. However, because of their lighter weight, modular systems may be more
susceptible to falling over during the erection of the system, due to factors 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.

4.3 STRIPPING FORMWORK

Stripping formwork can be one of the most hazardous phases of concrete
construction. While falling objects are the primary hazard, there may also be fall
hazards as a result of floor collapse and manual tasks hazards from a person
working in awkward postures, repetitive handling of materials and limited task
variety. As with formwork erection, the stripping operation must be carried out in an
orderly, progressive manner.

4.3.1 Work method statement

The Workplace Health and Safety Regulation 1997 requires the preparation of a
work method statement for ‘high-risk construction activity’.

A work method statement for the stripping operation should be prepared and
provided to those who will be involved in this high risk activity. The work method
statement should detail factors such as the following:

• the number of persons in the stripping crew;

• the sequence of stripping activities – this would need to detail how the frames
and/or other supports should be removed (that is, how far U-heads are to be
lowered);
• whether the support system is to be completely removed in a zone prior to
removal of the formwork deck or whether the supports are to be lowered slightly
but still remain under the formply while it is being removed;

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• when back-propping is required or only part of the support system is to be
removed, how the structural members are to remain in place and/or the type and
layout of members that will replace the formwork system; and

• any other special requirements involved in the stripping and or building process
(e.g. Checking of back-propping after post-tensioning).

4.3.2 Bond reduction

Stripping of formwork will be aided by reducing the bond between the form material
and the concrete. The bond will be dependent on the material characteristics and
the smoothness of the form material. The use of a liquid bond breaker on wall and
column forms is one way of reducing the strength of the bond. However, the use of
bond breaker on floor forms is not encouraged because of the slip hazard that may
result.

4.3.3 Certification prior to stripping

Prior to commencement of the stripping operation, a competent person should

provide written certification that formwork can be removed. This certification should
be based on a professional engineer’s specifications for the building, the strength of
the concrete mix and the time period that has elapsed since the pour. A professional
engineer will also be required to have input into the stripping work method 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.

4.3.4 Exclusion zone

Only persons involved in the stripping operation should be permitted in the area to
be stripped. Stripping are as should be cordoned off and signs should be displayed.
The signs should require persons to keep out of the area (e.g. “Danger - Formwork
stripping in progress – authorised persons only”). It is preferable to restrict access to
the whole floor where soffit stripping is taking place and this should reduce the
quantity of signage and barricades required. Where other trades are required to
work on the same floor during stripping of walls, columns or small sections of soffit,
the principal contractor or employer should ensure that stringent controls are applied
that prevent other persons from entering the stripping area.

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4.3.5 Drop stripping

‘Drop stripping’ is a term sometimes used to describe the method used when all of
the formwork support system is removed and the formply is allowed to drop to the
floor either by its own weight or by persons levering it off. In general, this method of
stripping should not be used to strip formwork. It can be hazardous because the
formply is likely to fall in an uncontrolled manner and can strike persons underneath.

However, in some situations, sheets can be dropped to the floor provided the
following is ensured:

• The formwork support system (e.g. props or frame) is only removed from under
the sheet to be dropped. Once the sheet is dropped the process progressively
continues until all sheets are dropped; and

• The person levering off the sheet is not at risk of being struck when the sheet
falls to the floor, keeping in mind that sheets may fall at an angle due to their
large surface area and effect of the air – for example, the person does not stand
directly under the sheet but stands far enough away and uses a pinch-bar to
lever the sheet off. It should be noted that this method can only be used on
relatively low ceiling heights unless the person can be positioned on a working
platform or elevating work platform. The advantage of using a platform is that the
person will generally be able to get closer to the sheet to be removed without
being at risk.; and

• The formwork system and sheets are not left in a haphazard manner on the floor
but are placed in stacks and progressively removed from the floor area.

Formwork removal must be carried out in a systematic manner, such that the deck is
progressively removed as the support system is gradually removed. One way to
remove the formply is by partially lowering the support system and then dropping the
segment of the deck (sheet) onto the support system. This is preferable from a
manual tasks perspective also as it eliminates the need to lift sheets of ply from
ground level.

4.4 CRANE AND LOAD HANDLING SYSTEMS

The Workplace Health and Safety Regulation 1997 outlines the requirements for
edge protection which may be used as a control measure where there is a risk a
person could fall during construction work.

All edge protection used in relation to crane and load handling systems must comply
with the requirements for edge protection detailed in the Workplace Health and
Safety Regulation 1997.

4.4.1 Loading materials during formwork construction

Materials including stacks of ply, forms, bearers and joists are sometimes lifted onto
a deck during formwork erection and before the deck is signed over. Stacked

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materials create point loadings which the formwork structure may not be designed to
bear. Materials should be stored only where and when the deck is able to bear the
load.

Formwork is not suitable for any loading until it is fully secured, that is, the deck is in
place with tie-ins and back-propping complete. In practice, some loading often
occurs before the deck is completed, for example, unloading pallets of ply and joists
used to continue the deck.

To minimise the risk of collapse and other hazards:

• formwork drawings should clearly identify the maximum (pre-pour) point loadings
for the deck;
• point loadings should not exceed the maximum weight specified by a formwork
designer or professional engineer;
• crane crews should be notified when an area of deck is ready to take a load, and
where that load should be placed;
• crane crews should not lift materials onto the deck until there is a designated
lifting zone;
• loads should only be placed in the area(s) designated as safe;
• loads must not be placed on the formwork deck if the formwork documentation
prohibits loadings;
• delivery of materials to the site should be planned so that loads are not lifted onto
unsecured decks; and
• prior to persons leaving the site, materials and equipment should be secured to
prevent them being moved by wind.

4.4.2 Access for persons slinging loads

Safe access must be provided for persons slinging and unslinging loads. Ladders
used by doggers while slinging loads should be secured to prevent movement.

The Workplace Health and Safety Regulation 1997, workers are not permitted to
work where they are at risk of falling 2 metres or more unless suitable control
measures are in place.

‘Permitted work’ is defined in the Workplace Health and Safety Regulation 1997.

A dogger or other person working at 2 metres or more above the deck must be
provided with adequate fall protection, unless the person is performing ‘permitted
work’.

Use of fall arrest systems for persons slinging formwork loads is usually impractical
and is not recommended.

It may be more practical to fit platforms and edge protection to lift forms to protect
persons when slinging the loads. The platforms must be at least 450 mm wide.
Persons required to access the platforms from ladders should have a safe means of

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access provided between the ladder and platform. They should not climb over the
top of the edge protection.

4.4.3 Lifting gear

Guidance on the use and inspection of chains, wire ropes and synthetic slings is
provided in the following publications:
• AS 2759 – Steel wire rope – Application guide
• AS 3775.2 – Chain slings – Grade T – Care and use
• AS 4497.2 – Roundslings – Synthetic fibre – Care and use
• AS 1353.2 – Flat synthetic-webbing slings – Care and use
• “A Guide for Doggers” (Workplace Health and Safety Queensland).

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); and
• 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.

4.4.4 Lifting formwork materials

Crane-lifted loads should be slung and secured so that the load (or any part of it)
cannot fall, as follows:

• tare mass of wall, lift or column forms should be provided on site with formwork
documentation and made available for inspection by all interested parties;
• safe working load mass should be clearly marked on bins;
• lifting boxes should be appropriate for the material being lifted, and be engineer-
designed and certified;
• four chains (one in each corner) should be fitted to lift boxes;
• specifically-designed lifting boxes should be used to lift smaller components (e.g.
spigots, U-heads, base plates and couplers). Boxes should have enclosed sides
or robust mesh (with openings less than the minimum size of materials being
lifted);
• lifting boxes should be inspected and maintained, and inspection records kept;
• loads within lifting boxes should be secured against movement;

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• materials should not be stacked higher than the side of the box unless they are
adequately secured, but at no time should the box become top heavy;
• formwork frames should either be tied together or lifting slings should be wrapped
around the load;
• loads of joists or bearers should be strapped together before lifting;
• use tag lines as required to control loads and well as forms;
• formply loads should be strapped together and lifted in a flat position; and
• ensure where possible all loads are supported with dunnage and the load is
uniformly distributed over the supporting surface.

4.4.5 Lifting lugs

Slings attached to lugs or holes cut into part of the load are often used to lift bins,
and wall, lift or column forms (instead of wrapping the lifting slings around the load).
Information verifying the structural adequacy of the lifting points should be available.

The certification should be provided by a professional engineer who should verify:

• the structural adequacy of the lifting lug; and
• the means of attachment to the load (usually welded or bolted to the load).

4.5 USE OF LADDERS

The Workplace Health and Safety Regulation 1997 specifies requirements for the
use of ladders in construction work.

Ladders are used both to gain access onto an area and for persons to carry out
permitted work including access and inspection. The Workplace Health and Safety
Regulation 1997 defines permitted work as ‘Work that can be done using only one
hand, while maintaining three other points of contact with the ladder.’

Ladders should be secured, either:

• attached at the top; or
• held firmly at the base by another person.

Where practical, alternatives to ladders such as work platforms or stair access

systems should be used.

Ladders must be used in accordance with the requirements of the Workplace Health
and Safety Regulation 1997, including:

• ladders must not to be used for work other than permitted work ;
• single ladders must not exceed 6.1 metres. Extension ladders not to exceed 7.5
metres;
• ladders must be industrial ladders with a load rating of at least 120 kilogram;
• ladders must be secured against movement; and
• single and extension ladders must be placed at an angle of between 70 degrees
and 80 degrees to the horizontal, except in some rare situations where this is
impractical.

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Other issues regarding the safe use of ladders include:

• a person’s feet should not be higher than 900 mm from the top of the ladder ;
• ladders should be set up on a firm, level surface. They should not be used on
scaffolding or Elevated Work Platforms to gain extra height;
• ladders should not be handled or used if they may come into contact with
electrical power lines. Metal or metal reinforced ladders should not be used in the
vicinity of live electrical equipment (timber ladders often have metal running along
their length); and
• ladders must not be positioned above or adjacent to openings or edges where a
potential fall could occur. Work platforms with edge protection should be
provided in this instance.

Ladders can only be used if equipment can be operated with one hand. Activities
requiring use of both hands must not be performed while standing on a ladder, for
example:

• removing tie bar from wall and column forms during form stripping – this usually
requires both hands and/or the use of a ‘tie-bar puller’;
• carrying timbers, formply, props or frames; and
• using power tools, such as circular saws.

Ladders used for access must extend at least one metre above the accessed
surface. Ladders should not be used in access ways or where there is pedestrian
traffic, vehicles or mobile plant.

AS1657 – (fixed platforms, walk ways, stairways and ladders-design, construction

and installation) must be complied with where fixed or permanent ladders are
provided

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5. FALLING OBJECTS
The Workplace Health and Safety Regulation 1997 describes control measures that
must be implemented to protect persons from falling objects during construction
work.

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.

Relevant persons have an obligation to workers and other persons who could be
injured or killed by any falling object during formwork activities.

The Workplace Health and Safety Regulation 1997 must be complied with to protect
persons from falling objects during construction work. In particular, the Workplace
Health and Safety Regulation 1997 requires the following when erecting or
dismantling formwork:

• closing adjoining areas to prevent objects falling on or hitting people;

• erecting perimeter containment screening along each part of the building from
where objects could fall; and
• ensuring control measures to prevent screen components from falling are in
place during erection, extension or reduction of perimeter containment screening.

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.

5.1 PREVENT THE OBJECT FROM FALLING.

Controls should be applied at the source to prevent objects from falling, that is,
eliminate the risk. This is the most effective control to prevent injury or death caused
by falling objects.

Good housekeeping practices are the most effective way of preventing small objects
from falling. Ensure items are cleaned up and kept away from edges, voids and
penetrations.

One control measure to prevent objects from falling is the use of perimeter
containment screens. This Code recommends that perimeter containment screening
be provided as a control measure for falling objects with equal regard for a person’s
safety and protection on site as well as for the protection of the public in adjoining
areas.

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5.1.1 Perimeter containment screening

The Workplace Health and Safety Regulation 1997 outlines particular requirements
for perimeter containment screens.

Containment sheeting is a protective structure fixed to the perimeter of a building,

structure or working platform to prevent objects and people from falling. Containment
sheeting should be used around the perimeter of a building or structure during
construction, and especially during formwork erection or stripping. It is usually
sheeted with:
• timber;
• plywood;
• metal or synthetic mesh; and
• metal or synthetic sheets.

Containment sheeting may be supported by the building, structure, or specially

designed scaffolding. It must extend at least one metre above the working surface.
When formwork is being erected or dismantled in the immediate vicinity of the
screening, the screening should be a minimum of two metres above the working
deck/stripping area.

When selecting containment sheeting consideration must be given to:

• ability to support or contain imposed loads including building materials,
equipment and waste materials
• ability to contain ejected objects;
• pattern and frequency of fixing points;
• degree of protection required from rain or washing down operations;
• chemical reactivity;
• flammability;
• light transmission requirements (refer AS 1680 for guidance);
• ventilation requirements (refer AS 1668.2 for guidance);
• frequency of inspection;
• wind loads on the supporting structure;
• gaps created by a fixing method; and
• the ability for the containment sheeting to move within the supporting structure.

Perimeter containment screens used for formwork must be placed in position prior to
formwork erection commencing and are not to be removed until all stripping is
completed and all formwork materials are removed from the underside of the
concrete as formed and/or removed from or stacked on the floor.

5.2 BUILDING STEP-INS

Perimeter containment screens must extend above the formwork erection area so
that materials cannot fall to the ground or other area where persons may be. Where
the horizontal surface under construction steps in from the building perimeter, such
as in the case of a plant room on a building roof, the perimeter screens must be
erected to a height that will prevent any materials falling to the ground.

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One example of an acceptable method to prevent falling objects is illustrated in
diagram 6. In this example the outside edge of the “step – in” structure is six metres
from the perimeter containment screen. The angle of an imaginary line from the top
of the screen to the top of the formwork platform is an angle of 45 degrees with the
horizontal.

Plant room

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.

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 a professional

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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; and
• the impact loadings of falling materials; and
• marking with their safe working load if they can be accessed as a platform.

5.4 PRIOR TO LIFTING

Prior to lifting the following should take place:

• formply, wall and column forms and other materials should have concrete
removed to ensure it does not fall onto persons below; and
• an inspection carried out to ensure all loose materials and tools are removed
from loads to be lifted.

Reference should also be made to section 4.4.4 of this Code : ‘Lifting formwork
materials’.

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6 HEALTH CONCERNS
6.1 NOISE

The Workplace Health and Safety Regulation 1997 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.

Reference should be made to the Queensland Noise Code of Practice 2004 for
further information about managing noise exposure as a risk to workplace health and
safety.

6.2 DUST

The Workplace Health and Safety Regulation 1997 details requirements for
managing the workplace health and safety risk associated with hazardous
substances.

The Workplace Health and Safety Regulation 1997 describes a number of

obligations that must be met about silica dust. While concrete itself is not a
hazardous substance, high levels of silica dust can be produced during formwork
processes. A hazardous substance 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.

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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.

6.3 MANUAL TASKS

Manual tasks include any activity where persons grasp, manipulate, carry, move (lift,
lower, push, pull), hold or restrain a load. Nearly all work done during the erection,
altering and/or dismantling of formwork involves manual tasks (e.g. erecting
formwork frames, handling sheets of ply, unloading vehicles or using hand tools such
as hammers or saws).

The Queensland Manual Tasks Code of Practice 2000 provides information about
how to prevent or minimise exposure to risks that contribute to/or aggravate work
related musculoskeletal disorders.

6.3.1 Control measures for manual tasks

Control measures for manual tasks fall into two major categories – design and
administrative controls.

Design controls

Design controls make changes to the work area, tools or equipment or, the way a job
is done and/or the provision of mechanical aids to reduce the effort required to do
the job. Design controls are preferred as they are permanent and can eliminate or
minimise exposure to risk factors.

Examples of design controls include:

Job design and redesign

• use more modern formwork systems which incorporate newer technologies;

• use alternative formwork techniques, such as, table forms or if using traditional
formwork systems use materials such as shorter length bearers, joists and
smaller sheets of ply which are easier to handle; and
• store materials and equipment as close as practical to the work area and in a
manner that facilitates ease of handling.

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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 minimized; and
• 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
obligation holders, including manufacturers and suppliers, should consider the
manual tasks risks.

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7. SPECIAL REQUIREMENTS FOR WALL AND COLUMN
FORMS
7.1 BRACING FOR WIND LOADING
Wall and column forms should be designed to withstand wind loading prior to, during
and after the concrete pour. The bracing and forms should not be removed from the
cast element until it can safely withstand potential impact loads and wind loads.

Prior to stripping operations a competent person as described by this Code must

provide written certification that the formwork can be removed.

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 a professional
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 manufacturer’s 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; or
• Coil bolts. The correct operation of coil bolts is greatly dependant on their being
installed in accordance with a manufacturer’s 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.

7.2 ACCESS PLATFORMS

Suitable access for doggers, steel fixers and concreters should be provided and may
include mobile scaffolding, purpose built work platforms or elevating work platforms.
Edge protection should be provided on the access platforms. The access method
should allow adequate room for a person and be positioned at a height and distance
from the form so as to minimise movement and a person’s exertion. Any concrete
pouring system should permit adequate space for a person to stand with edge
protection provided. All mobile work platforms should have their castors locked at all
times except when moving the mobile platform. Platforms should also be designed
to resist any side loading that may be applied during a concrete pour to ensure the
platform does not overturn. Aluminium scaffolding may not have adequate self

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weight to ensure this. The Queensland Scaffolding Code of Practice 2004 provides
additional guidance on the design and use of scaffolding.

7.3 LIFTING METHODS

Wall and column forms should be provided with lifting points that have been
designed by a professional engineer. Documentation must be available that verifies
this. Holes cut with oxy-acetylene torches are not recommended as they may
damage the form, are inaccurate and may make it difficult to attach lifting gear.
Where lifting lugs are attached to the form the weld size and length should be
specified by a professional engineer and the manufacturer should ensure that the
weld complies with the professional engineer’s requirements (that is, is of the correct
size and has adequate weld penetration).

Wall and column forms must only be lifted with a positive lifting system such as lifting
lugs or by slinging the lifting slings around the form such that the form cannot slip out
of the slings. Purpose designed lifting lugs are preferable to slinging the load
because there is less risk of the load becoming inadvertently disconnected from the
crane hook.

Suction between two members must never be permitted for lifting.

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8. SPECIAL REQUIREMENTS FOR SLIP FORMS AND
JUMP FORMS
This section applies to slip forms, jump forms and crane lifted forms that incorporate
working platforms and enclosed cells in which persons are required to work.

Slip forms and jump forms are the terms given to self-climbing formwork systems
specifically intended to construct concrete walls and columns in high rise buildings
and other concrete structures such as chimneys. In slip forms, the climbing is
usually carried out continuously during the concrete pour. With jump forms, the
climbing is done in steps, following the concrete pour. The term “climb form” is also
used to describe a slip form or jump form. The power for the climbing operation can
be provided in a variety of ways, but usually by means of hydraulic rams or electric
motors connected to climbing feet or screw shafts.

Slip forms and jump forms usually consist of a number of decks and may also be
fitted with trailing screens that are suspended from the form. As with perimeter
screens, trailing screens may provide edge protection for persons, prevent materials
from falling; provide support for work platforms or a combination of these uses. No
two slip forms or jump forms will be identical because their design depends on the
size and configuration of the 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. While most of the information in this
section applies to slip forms and jump forms, some of the principals may also apply
to crane-lifted forms.

When designing and operating these types of form, the following issues should be
addressed:

• provision for safe access to all areas and work platforms;

• control of risk associated with working at height;
• provision of sufficient working space and head room;
• specification of appropriate manual handling methods for shutters and other
components. As an example, the use of cranes to lift shutters and provision of
safe access for persons attaching slings to shutters; and
• provision for retrieval of an injured or incapacitated person from any work area
located within the structure.

It is acknowledged it may not be practicable to provide an access system and

working environment on a jump form or slip form that are of the same standard as
elsewhere. This is primarily due to building characteristics and weight limitations. A
designer, must endeavour to minimise potential hazards.

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8.1 ACCESS AND EGRESS
Access to the form may be provided in a variety of ways including one or more of the
following:
• personnel and material hoists on the building;
• permanent stair systems in the building;
• a trailing stair system suspended from the slip form or jump form; and
• a trailing ladder system.

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; and
• written procedures are implemented to ensure the total acceptable number of
persons on the form is not exceeded.

The Workplace Health and Safety Regulation 1997 specifies requirements for the
use of ladders in construction work.

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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8.2 WORKING PLATFORMS AND PENETRATIONS

The Workplace Health and Safety Regulation 1997 specifies requirements for
platforms.

The requirements for platforms listed in the Workplace Health and Safety Regulation
1997 also apply to slip forms and jump forms. However, the following points
highlight specific issues that may apply:

• all penetrations should be covered by formply that is secured in position or should

be provided with leading or perimeter edge protection;

• when placing steel or pouring concrete into a form, controls should be provided to
prevent a person falling into or off the form. This becomes more of an issue
when the width of the form is greater than 225 mm prior to placement of
reinforcing steel. A person working in proximity to projecting reinforcing steel or
other objects must be protected from the risk of being impaled by these objects.
Suitable controls may include edge protection on the internal side of the working
platform or sheets of steel re-enforcement mesh temporarily placed on top of the
form that is, the steel can be fed through the gaps in the mesh;

• all platforms that may be affected by uplift should be positively secured so that
uplift cannot occur. Uplift can occur from wind loading or when a platform is out-
of-level and unsecured. In the latter instance, the platform can see-saw when a
load is applied to the end of the platform and then drop a person off the platform
if one of the platform supports moves. This may be the case where work
platforms are supported by a trailing screen on one side and a parapet of the
building on the other; and

• where individual cells of the form are climbed at different times, edge protection
should be provided on each of the raised cells.

8.3 TRAILING SCREENS AND PLATFORMS

Trailing screens can provide edge protection, a means of preventing falling objects
and be designed to incorporate working platforms. Where platforms are provided
these are usually for the purpose of patching the building or carrying out minor
repairs, and for access for persons climbing the form. A designer of formwork will
specifically need to address all issues for which the trailing screen system is
designed. The following issues must be included in the design:

• a suitable design loading for any platforms on the trailing system. As a guide,
platforms should be designed to support a minimum load of 2.5 kPa. A designer
may reduce this if the number of persons is strictly limited and controls are
implemented on site to ensure this. If the design load is less than 2.5kPa, signs
should be fixed to the platforms that state the maximum load permitted in
kilograms. Persons on site should be made aware of the maximum loading that

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 may be applied to the trailing platform and this should be stated in documentation
kept on site;

• adequate controls should be provided to control the risk of falling materials (see
section 5 of this Code for further guidance); and

• all platforms should be secured to prevent uplift or any other movement

Reference should also be made to the requirements specified in the Workplace

Health and Safety Regulation 1997 in relation to ladders and edge protection.

Except where it is impractical to do otherwise, a person should not be located on

trailing platforms while the platforms are crane lifted. If a person is located on a
platform while it is being lifted by a crane, the following controls must be
implemented:

• a person should be prevented from falling down any gap that may exist on the
inside edge of the platform that is, between the platform and the wall being
constructed. It is preferable to provide edge protection on the inside edge to
ensure this. Fall arrest harnesses may be provided for workers as long as
workers are trained in their safe use and a rescue procedure for retrieval of
workers following a fall has been prepared;

• persons on the platform hold at least a dogger or rigger certificate or a person

with such a certificate is also located on the platform as it is lifted;

• a clear method of communication between the crane operator and the dogger
responsible for directing the lift exists that is, a whistle or two way radios; and

• any crane making the lift complies with the requirements for cranes used to lift
persons specified in AS 2550 : Cranes, hoists and winches – Safe use.

8.4 CLIMBING THE FORM

It is important to ensure the different parts of the form remain level during the
climbing process. Climbing is usually carried out using a series of climbing devices
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 on the structure or structural
members may be overloaded. There should therefore be a system to ensure that
the form does not go out-of-level during the climbing procedure. This system may be
an automated system or may rely on operators stopping the climbing process. The
following must be ensured:

• only persons directly involved with the climbing process should be located on the
form during the climbing process;

• any potential nip or shear points where a person could be injured during the climb
are identified and controlled;

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• all obstructions on the form have been removed prior to the form being climbed.
A ‘sign-off’ procedure for this should be provided. This includes the removal of
‘Z-bars’, ferrule bolts and other material that would snag on the structure if they
were not removed; and
• services including electrical cable and water pipes have been designed so that
they will not rupture or snag as the form is climbed.

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; and
• 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.

8.6 HEALTH ISSUES AND AMENITIES

Adequate ventilation and access to all cells in jump forms or slip forms should be
provided. It is difficult for persons to spend extended periods in cells due to the heat
and cramped working conditions. Allowance should be made for these issues and it
may be necessary to specify maximum times for particular cells depending on
temperature, humidity and cell size. These times should be developed as part of a
work method statement following consultation between the workers and their
employer.

Adequate ventilation and access should also be provided within cells and it may be
necessary to provide ventilation grills or accessways in the cells.

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Clean drinking water should be provided on the top level of the slip form and jump
form. On larger slip forms and jump forms it may be necessary to provide clean
drinking water on other levels.

A chemical toilet should be provided on the top of the jump form.

8.7 ENGINEERING ISSUES

The design of jump forms and slip forms is more complex than the design of
formwork systems for floors. Greater technical input from a designer is required
including consideration of wind loading. For this reason, the slip form or jump form
designer must be a professional engineer.

The jump form or slip form designer must be involved both in the initial design of the
form and in addressing ongoing design issues that will occur during form erection
and during the life of the building project. Many of the design problems associated
with jump forms and slip forms will not become apparent until the job is progressing,
and it is likely that alterations to the design of the form will be necessary. The
designer must therefore inspect the form on site and work closely with persons
involved in its operation, and the principal contractor, to determine if difficulties are
being encountered.

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; and
• consideration of rescue procedures that may effect 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.

8.8 EMERGENCY ISSUES

Fire extinguishers, hoses and other means of fire prevention and control must be
provided on the jump form or slip form in accordance with relevant legislation.

Emergency procedures for the jump form or slip form must be developed,
documented and implemented. Persons must be trained in these procedures and a
list of persons who have received the training must be documented.

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The emergency procedures must include, but not be limited to the following:

• the method of alert in the event of an emergency and the method of extracting
persons from each location or cell that the persons have access to or could fall
into;
• when to evacuate persons from the form;
• evacuation muster points both on and off the form;
• training in the use of fire extinguishers;
• identifying persons responsible for ensuring evacuation takes place;
• rescue procedures in the event of severe medical conditions;
• identifying persons responsible for rescuing workers; and
• rescue training for persons involved in rescuing others, where outside experts will
not be responsible for performing the rescue.

Where the form can be accessed using cranes on site, a first aid box for emergency
rescue of injured and incapacitated persons must be readily available and accessible
at all times while work is being undertaken.

Response to emergency situations must be considered during formwork design

stages and in an ongoing way during construction. Emergency situations requiring
evacuation of an injured worker from a formwork ‘cell’ need to consider how to safely
remove an immobilised or unconscious person. This may include creating
emergency access holes and doorways through decks and screens. Procedures
must identify how to access lift-voids and other areas, including cells within the core
which may have limited access.

Emergency services contacts must be clearly identified and available. These must
be nominated by all parties on site, including the principal contractor, sub-contractors
and workers.

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APPENDICES
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.

Cell 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.

Competent person 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—
(i) sound knowledge of relevant Australian Standards,
relevant codes of practice and other relevant legislation;
and
(ii) sound knowledge of, and competence in, the risk
management process for the erecting, altering and
dismantling of formwork, including—
o hazard identification and risk assessment; and
o measures to control exposure to risks; and
o safe work practices and procedures; and
o how to plan and prepare formwork.

Containment sheeting A protective structure fixed to the perimeter of the

building, structure or working platform to contain objects
and prevent them from falling. (See the Workplace Health
and Safety Regulation 1997 for specific requirements
relating to perimeter containment screening).

Edge protection A barrier to prevent a person falling erected along the

edge of-
a) A building or other structure;
b) An opening in a surface of a building or other
structure; or
c) A raised platform.

False deck A deck provided to prevent workers falling 2 metres or

more and/or provided as a working platform (different to
the ‘pouring deck’).

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Form 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.

Formwork designer 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.

Formwork frame A structural assembly, a number of which are used to

support a formwork deck. Bearers are placed directly on
these frames.

Horizontal member 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).

Intermediate platform A platform at least two planks wide, located less than 2
metres above a continuous deck.

Joist 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.

Modular formwork
systems A formwork system that is specifically designed for
formwork and consists of components that are not
designed to be used with other systems.

Perimeter edge
protection 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).

Pouring deck A deck on which concrete is poured.

Prescribed Occupation A principal contractor or employer must not allow a person

to perform work (and a person must not perform work) in
a prescribed occupation unless the person has
appropriate authority to perform work in the prescribed
occupation. A person has appropriate authority to
perform work in a prescribed occupation if—
o the person holds a certificate to work in the
occupation issued under the Workplace Health
and Safety Regulation 1997; or

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 o the person is a trainee in the prescribed
occupation.

Professional Engineer A person who is a registered professional engineer under

the Professional Engineers Act 2002 (Qld); and who has
appropriate experience and competence in the design of
formwork.

Prop 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.

Vertical member A vertical structural member which may or may not form
part of a frame, also known as standard, vertical tube.

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APPENDIX 2: SAMPLE ENGINEER’S CERTIFICATION LETTERS

(A) Engineer’s Certification Letter – NO Variation to Design

………………………………….

………………………………….

………………………………….

………………………………….

Dear Mr ……..

Project ……………………………………

I certify that the formwork system detailed below has been designed in accordance
with Australian Standards AS3610 – Formwork for Concrete and AS3600 – Concrete
Structures and the Project documentation including the structural engineering
drawings and specification. The system is detailed on the drawings and
documentation listed below.

Drawing Number Drawing Name

Specifications

Yours faithfully

SIGNATURE
Engineer’s Name

RPEQ No.

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(B) Engineer’s Certification Letter – Variation to Design

……………………………………

……………………………………

……………………………………

……………………………………

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

SIGNATURE
Engineer’s Name

RPEQ No.

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APPENDIX 3: CONSTRUCTION CHECKLIST
(Note, ‘#’ denotes an item that, if not passed by the competent person, must be referred to the
Professional Engineer. All other items not passed by the competent person must be corrected on site
and certified by the competent person when he/she is satisfied.)

Loads
• What are the stacked load limits at all stages?
• Are the stacked materials on spreaders?
# Will the loads be exceeded by any construction procedure?

Materials
# Are the correct form materials being used?
• Is the formface appropriate to the finish required?

Formwork Frames
# Are the formwork frames in the correct location and correct number?
• Are they to dimension and within tolerance?
• Are they accurate to line, level and plumb?

Bracing/Props
# Are there different props or braces to the ones indicated on the formwork
drawings?
• Are the props plumb?
• Are all loads centrally placed?
• Are supported elements wedged and nailed?
• Are props straight?
• Are base plates on adequate foundations?
• Is the bracing correct?
• Is the bracing firmly connected?

Fixing
• Is the nailing/screwing adequate?
# Are the ties the correct type?
# Are they on the correct grid?
• Are all ties, clamps and bolts tight?
• Are wedges tight and nailed?
# Are connections between traditional formwork and modular formwork correct?

Back-Propping
# Is the back-propping system correct?
# Are the number of floors required for back-propping correct?

Cleanliness
• Are the formfaces cleaned?
• Is any damage correctly repaired?
• Is the correct release agent in use?
• Is it being correctly applied?
• Has all debris been removed from within the form?

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Watertightness
• 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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APPENDIX 4: SAMPLE STRUCTURAL (PRE-POUR) CERTIFICATE

Engineer’s/Competent Persons Name:…………………………. Telephone…………………..

Address: ………………………………………… ……………………………

FAX:……………………………………………….

Mobile: …………………………………………… Date: ……………………………..

Project: …………………………………………………………………….
……………………………………………………………………..

Level:………………………………. Area:……………………….

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 CONDITION WORK REQ’D

Yes/No??
Base Plates OK No
Frame spacing OK No
Frame bracing OK No
Frame extensions OK No
Bearer size and spacing OK No
Joist size and spacing OK No
Prop spacing OK No
Prop bracing OK No
Eccentric loading OK No
Prop inclination OK No
Timber condition OK No
Steel condition OK No
Nails in plates as req’d OK No
Column framing OK No
Column bracing OK No
Plywood fixing OK No

……………………………………. …………………………………
Engineer’s / Competent persons name Signature

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APPENDIX 5: DEFECTS COMMONLY FOUND IN FORMWORK SYSTEMS.

SOLE PLATES
(a) not levelled in or eccentrically placed
(b) inadequate load-carrying capacity of the ground and uneven bedding
(c) deterioration with time (e.g. Due to weather conditions)
(d) deterioration of load-carrying capacity of the ground, (e.g. Washouts)
(e) crushing due to inadequate load distribution from vertical and horizontal
members.

HORIZONTAL SUPPORTS
(a) folding wedges cut to too coarse a taper, not properly cleated, cut from wet
material
(b) inadequate lateral and torsional bracing, (e.g. Between telescopic centres,
centres carrying heavy loads over long spans, steel props supporting heavy
loads at, or near, maximum extension and between towers supporting
independent spans)
(c) horizontal members not centrally placed in forkheads
(d) inadequate supports to cantilevers, (e.g. Struts supporting deep beam sides
on the outer face of the structure)
(e) inadequate bearing areas to vertical supports and underside of principal
members causing crushing
(f) inadequate support to prevent overturning of deep principal members
because Stirrups or Forkheads often omitted
(g) bolted timber connections not staggered creating tendency to split out.

VERTICAL SUPPORTS
(a) inadequate bracing during erection
(b) support not plumb
(c) inadequate lateral ties and/or vertical and plan bracing
(d) no ties between standards at point of loading (most important where
telescopic centres are being supported)
(e) incorrect provision of props from floor to floor
(f) lack of rigidity of screw connections due to over-extension or lack of bracing
(g) adjustable steel props with nails, mild-steel bolts and reinforcing bars used in
place of correct pins
(h) omission of scaffold forkheads or supports, otherwise eccentrically loaded
without allowance having been made for this condition
(i) bearing plates distorted (top and bottom plates of steel props)
(j) inadequate or discontinuous bracing to scaffold.

GENERAL
(a) excessive tolerances in construction
(b) failure to check tightness of bolts, wedges, etc.
(c) failure to control vertical rate of placement of concrete
(d) failure to control placement of concrete, causing uneven loading of forms
(e) inadequate allowance for uplift of concrete under inclined forms
(f) inadequate allowance for the effects of vibration on joints
(g) inadequate allowance for stresses induced by prestressing, temperature and
moisture movements

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(h) no allowance for wind loading
(i) no allowance for the effect of vibration on ties, struts, braces, and wedges
(j) unrealistic assessment of stresses due to over-simplification of design
assumptions
(k) unequal load distribution between two or more members carrying a common
load.

© The State of Queensland (Department of Industrial Relations) 2005.

The State of Queensland makes no statements, representations, or warranties about the accuracy or completeness of, and you
should not rely on, any information contained in this document.

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