Concrete Pour Safety

Concrete pours involve multiple hazards including chemical burns, manual handling, plant movements, and formwork failure.
Wet concrete is highly alkalite (pH 12-13) and causes severe chemical burns to unprotected skin and eyes.
Burns from wet concrete may not be felt immediately — damage continues even after apparent removal from skin.
Concrete pumps operate under high pressure and the boom must be treated as a crane during placement.
Formwork and falsework must be inspected and approved with a permit to load before any concrete is poured.
The weight of wet concrete is approximately 2.4 tonnes per cubic metre — overloading formwork causes collapse.
Concrete delivery vehicles are heavy and have restricted visibility — banksmen are required at all times.
Vibration tools used to compact concrete can cause hand-arm vibration syndrome with prolonged daily use.
Concrete washout must be contained and disposed of properly — it must never enter drains or watercourses.
Communication between the pump operator, placing gang, and supervisor is critical throughout the pour.

Prevent burns	Wet concrete causes severe alkali burns that destroy skin tissue — gloves and waterproof clothing are essential during all pours.
Prevent collapse	Formwork overloading or premature striking causes catastrophic structural collapse — permit to load is mandatory before pouring.
Protect the environment	Concrete washout is highly polluting — just one washout entering a watercourse can kill aquatic life for miles downstream.

Do

Don't

Wear waterproof gloves, long sleeves, eye protection, and Wellington boots during all pours.
Confirm the permit to load has been issued for formwork before any concrete is placed.
Wash any wet concrete off skin immediately with clean water for at least 20 minutes.
Use a banksman to guide concrete delivery vehicles and pump trucks on site.
Maintain clear communication between the pump operator and the placing gang.
Monitor formwork for signs of deflection, leakage, or movement during the pour.
Follow vibration trigger times when using poker vibrators to compact concrete.
Contain all concrete washout in designated areas — never allow it to reach drains.
Plan the pour sequence and ensure adequate labour is available before starting.
Ensure emergency eyewash is available within reach of the concrete placing area.

DON'T handle wet concrete without waterproof gloves and protective clothing.
DON'T pour concrete without a valid permit to load for the formwork system.
DON'T ignore concrete on your skin — wash it off immediately to prevent burns.
DON'T allow concrete wagons to move on site without a trained banksman present.
DON'T operate a concrete pump boom without clear sight of the discharge point.
DON'T continue pouring if formwork shows signs of movement, bulging, or leaking.
DON'T exceed vibration exposure trigger times when using poker vibrators.
DON'T wash concrete into drains, watercourses, or uncontained areas on site.
DON'T kneel in wet concrete or allow it to collect inside boots or gloves.
DON'T strike formwork before the concrete has reached the required strength.

See also: Concrete Burns Prevention | Formwork Erection & Striking

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