CON/General/TBT-CON-034
Sprayed Concrete (Shotcrete) Application
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Toolbox Talk
Sprayed Concrete (Shotcrete) Application
Sprayed concrete is applied at high velocity through a nozzle to form structural linings in tunnels, retaining walls, and slope stabilisation works. The process generates significant dust, rebound material, and noise, and involves working with pressurised equipment in enclosed spaces. This talk covers the hazards of shotcrete operations and the controls every operative must follow during application.
Key Hazards
Silica dust inhalation from dry-mix shotcrete and rebound material
High-pressure hose whip or nozzle kickback injuring the spray operative
Chemical burns from accelerators and admixtures added to the concrete mix
Hearing damage from sustained high noise levels during spraying operations
Control Measures
- Wear RPE with a P3 particulate filter during all shotcrete application and rebound clean-up.
- Use forced ventilation in tunnels and enclosed areas to control dust and fume concentrations.
- Inspect all hoses, couplings, and nozzles before each shift for wear, damage, or loose connections.
- Secure hose connections with safety chains or whip checks to prevent uncontrolled movement.
- Wear chemical-resistant gloves and full-face eye protection when handling accelerator admixtures.
- Ensure hearing protection is worn by all personnel within the designated noise zone during spraying.
- Brief the nozzleman and crew on the spray sequence, mix design, and emergency stop procedures.
- Keep non-essential personnel clear of the spray zone to avoid rebound material injuries.
- Clean up rebound material regularly to prevent it accumulating and creating trip hazards.
Remember
- Wear P3 filtered RPE during all shotcrete spraying and when cleaning up rebound material
- Use forced ventilation in tunnels and enclosed spaces to control dust and fume levels
- Inspect hoses, couplings, and nozzles before each shift for wear, damage, or loose connections
- Secure all hose connections with safety chains or whip checks to prevent whip injuries
- Hearing protection is mandatory for all personnel within the noise zone during spraying
- Keep non-essential personnel well clear of the active spray zone at all times
Applicable Legislation: COSHH Regulations 2002 · Control of Noise at Work Regulations 2005 · CDM Regulations 2015 · Health and Safety at Work etc. Act 1974
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