Reinforcement steel bars and mesh are heavy, awkward, and have sharp cut ends that cause serious lacerations. Bundles of rebar are among the heaviest materials manually handled on construction sites. Incorrect lifting, carrying, and stacking of reinforcement causes back injuries, cuts, and crush incidents. This talk covers the safe handling of reinforcement steel on UK sites.
Key Hazards
Deep lacerations from sharp cut ends of reinforcement bars and mesh
Back and shoulder injuries from lifting heavy rebar bundles manually
Crush injuries from unstable rebar stacks toppling onto workers
Impalement on protruding vertical starter bars in foundations
Control Measures
Use cranes, excavators with lifting attachments, or telehandlers to move rebar bundles wherever possible.
Wear heavy-duty cut-resistant gloves when handling all reinforcement steel on site.
Cap all protruding vertical starter bars with mushroom caps or bend them over to prevent impalement.
Stack reinforcement on level ground using timber spacers and limit stack height to prevent toppling.
Cut rebar ends clean and deburr sharp edges before installation to reduce laceration risk.
Carry loose bars in pairs using proper grip and route planning to avoid trip hazards.
Establish exclusion zones beneath crane lifts when moving bundled reinforcement overhead.
Brief steel fixers on correct manual handling techniques and the use of mechanical aids.
Inspect all slings and lifting chains used for rebar bundles before every lift.
Remember
Use mechanical handling aids for rebar bundles wherever possible to reduce manual lifting
Wear heavy-duty cut-resistant gloves at all times when handling reinforcement steel
Cap all protruding vertical starter bars with mushroom caps to prevent impalement
Stack rebar on level ground with spacers and limit height to prevent stacks toppling
Inspect slings and lifting chains before every lift of bundled reinforcement steel
Applicable Legislation: Manual Handling Operations Regulations 1992 · LOLER 1998 · CDM 2015 · Personal Protective Equipment at Work Regulations 1992