Concrete Pouring and Formwork JSA – Job Safety Analysis
1. Introduction
Concrete pouring and formwork activities are critical in construction, especially for structural components like foundations, columns, beams, slabs, and walls. These operations involve several hazards including heavy lifting, falls, struck-by incidents, collapse of formwork, concrete burns, and exposure to moving equipment.
A Job Safety Analysis (JSA) ensures that all potential hazards are identified, risks are evaluated, and proper control measures are implemented before the job begins.
2. Purpose of This JSA
The objectives are to:
- Ensure the safety of workers during concrete pouring and formwork activities.
- Comply with OSHA, ISO, and local safety regulations.
- Minimize incidents caused by unsafe practices, equipment failure, or environmental factors.
- Promote hazard awareness among the workforce.
3. Applicable Standards & References
- OSHA 29 CFR 1926 Subpart Q – Concrete and Masonry Construction
- ACI 347 – Guide to Formwork for Concrete
- IS 456 – Code of Practice for Plain and Reinforced Concrete
- IS 14687 – Falsework and Formwork Safety
- ISO 45001 – Occupational Health and Safety Management Systems
- Company Safety Procedures
4. Scope of Work
This JSA applies to all activities involved in:
- Setting out formwork for foundations, beams, slabs, walls, and columns.
- Erecting and securing falsework and scaffolds for formwork.
- Installing reinforcement inside formwork.
- Pouring, compacting, and curing concrete.
- Stripping (removing) formwork after curing.
5. Step-by-Step JSA Process for Concrete Pouring & Formwork
Step 1: Job Breakdown
- Pre-job planning and site preparation.
- Delivery and storage of formwork materials.
- Erecting formwork and falsework.
- Checking formwork alignment, stability, and strength.
- Placing reinforcement and embedded fixtures.
- Preparing concrete mix or ensuring delivery schedule.
- Pouring concrete into formwork.
- Vibrating/compacting concrete.
- Leveling and finishing concrete surface.
- Curing concrete.
- Stripping formwork.
- Site cleanup.
Step 2: Hazard Identification
Key hazards include:
- Collapse of unstable or poorly braced formwork.
- Falls from height while working on elevated formwork or pouring decks.
- Struck-by injuries from falling tools or materials.
- Muscle strain from lifting heavy formwork panels.
- Pinching and crushing injuries while assembling/disassembling formwork.
- Contact with wet concrete causing skin burns or dermatitis.
- Noise and vibration hazards from mechanical vibrators.
- Trips and slips on wet or uneven surfaces.
Step 3: Risk Assessment Table
| Task | Hazard | Potential Consequence | Risk Rating | Control Measures |
|---|---|---|---|---|
| Delivering materials | Manual handling injuries | Back injury, strains | Medium | Mechanical aids, team lifting |
| Erecting formwork | Collapse, falling objects | Serious injury/death | High | Proper bracing, exclusion zone |
| Working at height | Falls | Fractures, head injury | High | Guardrails, safety harness |
| Pouring concrete | Splash/contact with skin | Chemical burns | Medium | Long sleeves, gloves, barrier cream |
| Vibrating concrete | Noise, vibration | Hearing loss, hand-arm vibration syndrome | Medium | Hearing protection, vibration-limited tools |
| Stripping formwork | Falling panels, sharp edges | Cuts, fractures | High | PPE, controlled dismantling |
6. Control Measures
A. Engineering Controls
- Use formwork systems designed and rated for expected loads.
- Install proper bracing and ties to prevent collapse.
- Provide safe access and egress (ladders, platforms, scaffolds).
- Use concrete pumps instead of manual lifting where possible.
B. Administrative Controls
- Appoint a competent person to inspect formwork before pouring.
- Follow manufacturer’s assembly instructions for proprietary systems.
- Conduct daily toolbox talks on specific hazards.
- Establish exclusion zones to prevent unauthorized entry.
- Sequence work to minimize simultaneous conflicting activities.
C. Personal Protective Equipment (PPE)
- Hard hat with chin strap.
- Safety shoes with steel toe.
- High-visibility vest.
- Cut-resistant gloves.
- Long-sleeve shirts and trousers.
- Safety goggles or face shield when pouring concrete.
- Hearing protection during vibration.
7. Roles & Responsibilities
- Site Manager – Approves work plans, ensures safety resources are available.
- Formwork Supervisor – Directs formwork assembly, verifies stability.
- Competent Person – Inspects formwork before, during, and after concrete placement.
- Concrete Crew – Follows safe pouring, vibrating, and finishing practices.
- Safety Officer – Monitors work, enforces PPE compliance, and conducts inspections.
8. Emergency Preparedness
- Rescue plan in case of falls or entrapment.
- First aid kits and trained personnel onsite.
- Emergency contact numbers posted at the site.
- Spill control plan for concrete spillage.
- Fire extinguishers available if using formwork treated with flammable coatings.
9. Best Practices for Concrete Pouring and Formwork Safety
- Never overload formwork beyond its design capacity.
- Keep walkways and platforms clear of obstacles.
- Avoid pouring in extreme weather without precautions (rain, heat, cold).
- Maintain continuous communication between pump operators and pour crew.
- Remove formwork only after concrete has achieved required strength.
- Dispose of waste materials in designated areas.
10. Sample JSA Form – Concrete Pouring and Formwork
Job Title: Concrete Pouring and Formwork
Location: ________________________
Date: ________________________
Supervisor: ________________________
| Task Step | Hazard | Control Measure | PPE Required | Responsible Person |
|---|---|---|---|---|
| Erecting formwork | Collapse | Proper bracing, inspection | Helmet, gloves | Supervisor |
| Working at height | Falls | Guardrails, harness | Helmet, harness | Crew |
| Pouring concrete | Burns | Gloves, sleeves | Gloves, goggles | Crew |
| Vibrating concrete | Noise, vibration | Hearing protection | Ear plugs | Crew |
| Stripping formwork | Falling panels | Controlled dismantling | Helmet, gloves | Crew |
11. Conclusion
A Concrete Pouring and Formwork JSA is essential for preventing accidents, ensuring regulatory compliance, and improving efficiency on construction sites.
Safe work is a combination of proper planning, hazard identification, competent supervision, and disciplined execution.
✅ Final Safety Reminder:
“A strong structure starts with safe practices. Build safely, build smart, build to last.”
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