Ironwork Installation (Gullies, Manholes)

Toolbox Talk Record

Ref: TBT-HWY-015  |  Issue: 1  |  Date: March 2026
PresenterProject
LocationDate

What?

Why?

Prevent manual handling injuryIronwork units are extremely heavy — mechanical aids and team lifts are essential to prevent back and hand injuries.
Public safetyIncorrectly set ironwork creates trip hazards and vehicle damage on public highways used by millions.
Traffic safetyWorking at road level in live carriageways requires full traffic management to protect workers from vehicles.
Do Don't
  • Use mechanical lifting aids such as manhole cover lifters for all heavy ironwork units
  • Wear heavy-duty gloves to protect hands from crushing when positioning ironwork frames
  • Set ironwork to the correct level using the SROH specification for the road type
  • Ensure traffic management is in place before starting any ironwork installation on highways
  • Protect hands and skin from mortar and concrete bedding with chemical-resistant gloves
  • Check for buried services adjacent to manholes and gullies before any breaking out
  • Use team lifts where mechanical aids are not available for heavy iron covers and frames
  • Barrier off open manholes and gullies to prevent falls while ironwork is being installed
  • Compact bedding material to specification to prevent settlement and rocking of covers
  • Inspect installed ironwork before reopening the road to confirm correct level and seating
  • DON'T manually lift heavy manhole covers alone — always use lifting aids or team lifts
  • DON'T leave open manholes or gullies unguarded while ironwork is being replaced
  • DON'T install ironwork without traffic management on any public highway or footway
  • DON'T set ironwork above or below the surrounding road surface outside tolerance limits
  • DON'T handle mortar or concrete bedding without chemical-resistant gloves and eye protection
  • DON'T drop heavy ironwork onto chamber walls — lower carefully to prevent structural damage
  • DON'T work in live carriageways without high-visibility clothing and signed traffic management
  • DON'T place fingers under ironwork edges when lowering covers into frames
  • DON'T reuse damaged or cracked ironwork — replace with new units to the correct class
  • DON'T backfill around ironwork frames without proper compaction to the SROH specification

See also: Footway Reconstruction Safety | Manual Handling Awareness