BRD/General/TBT-BRD-004

Bridge Deck Construction

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Bridge Deck Construction

Toolbox Talk Record

Ref: TBT-BRD-004  |  Issue: 1  |  Date: March 2026
PresenterProject
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What?

  • Bridge deck construction involves forming, reinforcing, and pouring the structural slab of a bridge.
  • Work takes place at height over roads, railways, rivers, or voids with significant fall risks.
  • Temporary works including falsework and formwork must be designed, checked, and approved before loading.
  • Reinforcement fixing on bridge decks requires edge protection and safe access across the steel.
  • Concrete pours on bridge decks are often large-volume and need detailed pour sequence planning.
  • The Work at Height Regulations 2005 and CDM 2015 apply to all bridge deck activities.
  • Wind exposure is typically greater on elevated bridge decks than at ground level.
  • Post-tensioning ducts and anchorages must be correctly positioned before the concrete pour.
  • Traffic management or railway possessions may be needed for work over live infrastructure.
  • Formwork striking must follow the temporary works procedure — never strip early without approval.

Why?

Prevent fatal fallsWorking at height over voids is the highest risk activity in bridge construction.
Structural safetyFalsework failure during a pour causes catastrophic collapse and multiple fatalities.
Legal dutyCDM and Work at Height Regulations require detailed planning for all bridge deck work.
Protect the publicWork over live roads and railways puts the travelling public at risk if uncontrolled.
Do Don't
  • Ensure all falsework is designed, checked, and signed off before loading.
  • Install full edge protection around the deck perimeter before access.
  • Follow the agreed pour sequence and concrete supply plan precisely.
  • Use safety nets or catch platforms where full edge protection is impractical.
  • Monitor weather conditions — stop work in high winds or heavy rain.
  • Brief all operatives on access routes and emergency procedures daily.
  • Confirm traffic management or possession is in place before starting.
  • Inspect formwork and falsework after each concrete pour stage.
  • Secure all loose materials and tools against wind uplift at height.
  • Coordinate post-tensioning activities with the specialist contractor fully.
  • DON'T load falsework beyond the approved design capacity.
  • DON'T work at deck level without edge protection or fall arrest systems.
  • DON'T strip formwork before the specified minimum curing period.
  • DON'T allow unauthorised access to the bridge deck during construction.
  • DON'T drop or throw materials from the deck onto areas below.
  • DON'T ignore temporary works inspection requirements between pour stages.
  • DON'T continue pouring if falsework shows signs of distress or movement.
  • DON'T work over live traffic without approved protection measures in place.
  • DON'T alter the pour sequence without the engineer's written approval.
  • DON'T store excessive materials on the deck beyond the design load.

See also: Bridge Construction Safety Awareness | Formwork and Falsework
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