Formwork and Shuttering Risk Assessment
Formwork and shuttering are critical parts of any concrete structure — they’re the molds that hold the shape until the concrete sets. But behind those frames lies a range of dangers: collapses, falls, trips, and even impalement injuries from exposed rebar.
A formwork and shuttering risk assessment helps you identify those risks before someone gets hurt. It’s a preventive process that ensures your temporary structures don’t become permanent problems.
Relevant Safety Standards and Regulations
OSHA Requirements for Formwork
Under 29 CFR 1926.703, OSHA specifies safe practices for formwork construction, support, and removal. It highlights the need for proper design and supervision.
HSE UK Guidance on Temporary Works
The UK HSE mandates that temporary works like formwork be designed, installed, and dismantled under strict control, using trained personnel and approved plans.
Indian IS Codes for Shuttering Safety
IS 14687:1999 and IS 2751 provide safety guidelines for centering and shuttering in concrete construction, emphasizing material quality and structural integrity.
Types of Formwork and Shuttering
Timber Formwork
Traditional, cost-effective, and easy to work with — but more prone to warping, cracking, and moisture damage.
Steel Formwork
Durable and reusable, but heavier. Needs cranes or mechanical handling and proper anti-rust maintenance.
Aluminum and Plastic Formwork
Lightweight and modular — ideal for repetitive structures. Reduced labor but requires careful handling.
Modular and System Formwork
Pre-engineered systems that increase speed and safety — often used in high-rise or industrial builds.
Common Hazards in Formwork and Shuttering
Collapse of Formwork
One of the most serious hazards — often due to improper anchoring, overloading, or design flaws.
Falling from Height
Workers assembling or striking formwork often operate at height — without proper platforms or harnesses, the risk is high.
Slips, Trips, and Sharp Edges
Wet surfaces, exposed nails, and scattered tools increase the chance of minor to serious injuries.
Manual Handling and Strain Injuries
Lifting heavy panels or braces can cause back injuries and muscle strains, especially without team lifting or mechanical aids.
Nail and Tie Wire Injuries
Untrimmed wires or exposed nails pose puncture and laceration risks — especially during removal or adjustment.
Poor Scaffold Integration
If scaffold and formwork systems aren’t aligned or connected properly, stability is compromised.
Steps in a Formwork Risk Assessment
Step 1 – Identify Hazards on Site
Look at the terrain, formwork type, height, weather conditions, and other trades working nearby.
Step 2 – Identify Who Could Be Harmed
Workers assembling or dismantling, nearby electricians or plumbers, and crane operators can all be affected.
Step 3 – Evaluate the Risk and Choose Controls
Assess how likely the hazard is to occur and how severe the outcome would be. Then decide on mitigation strategies.
Step 4 – Record, Share, and Train
Document all risks, assign control measures, and conduct training/toolbox talks before starting the work.
Step 5 – Monitor and Review Regularly
Daily checks are a must — especially before pours or during dismantling.
Control Measures for Formwork and Shuttering
Use of Quality Materials and Approved Designs
Don’t use warped or damaged formwork. Ensure all systems follow approved design drawings and load calculations.
Bracing and Anchoring Systems
Ensure horizontal and vertical bracing is tight and complete. Use base plates and anchoring for stability.
Pre-Use Inspection and Load Testing
Inspect for loose bolts, misaligned frames, or broken panels. Conduct trial loads for large structures.
Trained Workforce and Supervision
Only trained and experienced personnel should handle erection and dismantling. Supervision ensures errors are caught early.
Access Systems and Safe Platforms
Use ladders, scaffolds, or working platforms for safe movement. Avoid standing on unstable formwork.
Emergency Response Readiness
Have first-aid kits, communication devices, and rescue procedures on-site in case of a collapse or injury.
Hierarchy of Controls for Formwork Safety
Eliminate – Avoid Complex Temporary Structures
Design simpler molds or use pre-cast systems to minimize formwork usage.
Substitute – Use Lightweight Form Systems
Replace timber or steel with modular plastic systems to reduce strain and handling injuries.
Engineering Controls – Braces, Props, Frames
Use mechanical props, edge barriers, and shoring towers to support vertical loads.
Administrative Controls – Permits and Schedules
Assign task-specific permits, stagger trades to reduce overcrowding, and follow lifting schedules.
PPE – Gloves, Helmets, Safety Boots, and Eye Protection
Mandatory on all formwork jobs to protect from falling objects, sharp tools, and impact injuries.
Best Practices for Safe Shuttering
Formwork Striking Time and Load Consideration
Wait until concrete gains required strength before striking. Follow curing time recommendations.
Coordination Between Trades
Ensure electrical and plumbing teams aren’t cutting through formwork unintentionally. Hold coordination meetings regularly.
Maintaining Clear Access Routes
Keep walkways free of formwork debris and unused material. Install signage and directional indicators.
Real-Life Incidents and Lessons Learned
Case 1: Collapse Due to Poor Bracing
In a commercial project, poor diagonal bracing caused a formwork collapse during concrete pour. No injuries, but project delayed. Lesson: Bracing isn’t optional — it’s essential.
Case 2: Worker Injury from Improper Dismantling
A laborer was injured when a tie rod snapped back during dismantling. PPE saved his eyes, but he needed stitches. Lesson: Always follow proper removal sequences and use PPE.
Formwork Risk Assessment Template
Key Fields to Include
- Project and task details
- Type and height of formwork
- Hazard identification
- Risk evaluation (pre- and post-control)
- Control measures
- Person responsible
- Inspection and review records
- Emergency plan
How to Apply It On-Site
Use it during your morning briefing. Walk the site with the supervisor to verify controls. Keep a printed copy with the safety officer and site manager.
Risk Assessment – Formwork and Shuttering
General Information
- Project/Site Name: ABC Commercial Complex – Tower A
- Assessment Title: Risk Assessment for Formwork and Shuttering
- Location: Basement and Ground Floor Columns and Slabs
- Assessed By: Mahendra Lanjewar (Safety Officer)
- Assessment Date: 01 July 2025
- Review Date: 01 October 2025
- Activity Description: Erection, alignment, and dismantling of formwork and shuttering systems for concrete casting of columns, beams, slabs, and walls.
Formwork and Shuttering Risk Assessment Table
| Task | Hazards Identified | Persons at Risk | Risk Rating (Before Control) | Control Measures | Risk Rating (After Control) | Responsible Person |
|---|---|---|---|---|---|---|
| 1. Erection of formwork panels and supports | Collapse of formwork due to incorrect assembly or overloading | Formwork carpenters, nearby workers | High | – Follow approved formwork drawing – Use only tested formwork materials – Supervision by experienced foreman – Ensure proper bracing and leveling | Low | Site Engineer / Foreman |
| 2. Manual handling of panels, props, and boards | Strains, sprains, back injury | Workers handling materials | Medium | – Team lifting for heavy materials – Use mechanical aids where possible – Manual handling training for all workers | Low | Supervisor |
| 3. Working at height during formwork installation | Fall from scaffolding or platform | Formwork crew | High | – Provide scaffolds with guardrails – Use fall protection systems (harness, lifelines) – Permit to work at height | Low | Safety Officer |
| 4. Use of power tools (cutters, drills) | Electrical shocks, cuts, flying debris | All workers using tools | High | – Use properly insulated tools – Regular inspection and tagging – Wear PPE (gloves, eye protection) | Low | Electrician / Safety Officer |
| 5. Tripping on scattered materials and offcuts | Trips, falls, cuts from sharp materials | All site workers | Medium | – Maintain good housekeeping – Designate storage areas for material – Clear debris regularly | Low | Supervisor |
| 6. Dismantling of formwork after concreting | Collapse of structure, falling panels | Workers dismantling shuttering | High | – Wait for proper curing time (as per engineer’s instruction) – Dismantle in sequence – Use hand tools safely – Wear helmet and gloves | Low | Foreman / Site Engineer |
| 7. Struck by falling objects during shuttering | Head injury from falling props or tools | Workers below the activity zone | High | – Barricade area below – Use signage to restrict entry – Workers to wear safety helmets | Low | Safety Officer |
| 8. Fire risk from stored wooden formwork | Fire due to welding or sparks nearby | All workers in area | Medium | – Store formwork materials away from hot work zones – Keep fire extinguisher nearby – Conduct fire risk assessment if needed | Low | Fire Watcher / Safety Officer |
Risk Rating Matrix
| Severity | Likelihood | Risk Rating |
|---|---|---|
| 1 – Minor injury | 1 – Unlikely | Low |
| 2 – Moderate injury | 2 – Possible | Medium |
| 3 – Serious/fatal injury | 3 – Likely | High |
Formula: Risk Rating = Severity × Likelihood
Additional Notes
- PPE Required: Hard hat, safety boots, gloves, reflective vest, eye protection, fall protection kit (when working at height).
- Permit to Work: Required for working at height and near live electrical systems.
- Training: Workers must be trained in safe erection and dismantling techniques.
- Formwork Inspection: Daily checks before pouring concrete.
- Weather Consideration: No work during heavy wind or rain if elevated platforms are used.
- Toolbox Talks: Daily safety briefings before starting work.
Emergency Measures
- First Aid: On-site first aid kit with trained first aider.
- Rescue Plan: In place for fall incidents.
- Emergency Contact Numbers: Displayed at site notice board.
Review and Sign-Off
| Name | Designation | Signature | Date |
|---|---|---|---|
| Rupesh Wasnik | Safety Officer | [Signature] | 01-07-2025 |
| Rakesh Kumar | Project Manager | [Signature] | 01-07-2025 |
| Manoj Yadav | Site Engineer | [Signature] | 01-07-2025 |
Conclusion
Formwork and shuttering are the unsung heroes of construction — they shape the structure but can also bring it down if ignored. A smart, structured formwork and shuttering risk assessment not only ensures compliance but also saves lives and project timelines.
Think of it this way: if concrete is the heart of construction, formwork is the skeleton. Don’t let your safety frame crack. Plan well, inspect more, and train your crew right.
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FAQs
1. What is the most common formwork hazard?
Collapse due to poor bracing or overloading is one of the top hazards.
2. Can formwork fail even if designed correctly?
Yes, if it’s not installed properly, not inspected, or subjected to weather or vibration before curing.
3. How often should formwork be inspected?
Daily, before concrete pours, and after any environmental event (rain, vibration, etc.).
4. Is PPE enough for formwork work safety?
No. PPE is necessary but must be paired with proper planning, training, and engineered supports.
5. What’s the best material for safe shuttering?
Steel or modular systems are preferred for safety and durability, though plastic is also safe if installed correctly.
