Concrete Placement Activity Hazard Analysis
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Concrete placement and finishing operations on USACE and DoD construction projects involve a range of hazards that span chemical exposure, musculoskeletal injury, struck-by events, and respiratory illness. Portland cement is a known skin sensitizer and caustic agent. Silica exposure during cutting, grinding, and finishing operations is a documented cause of silicosis and lung cancer. EM 385-1-1 Section 24 addresses concrete and masonry operations specifically, with additional requirements from sections covering fall protection, PPE, and hazardous materials.
This Activity Hazard Analysis treats concrete placement and finishing as a Definable Feature of Work encompassing formwork preparation, concrete delivery and placement, vibration and consolidation, finishing, curing, and form stripping. The initial Risk Assessment Code of Medium (3) reflects critical severity (chemical burns, silica exposure, struck-by from concrete buckets) with occasional probability. Residual RAC of Low (5) assumes full implementation of engineering controls, wet methods for dust suppression, and proper PPE.
Concrete operations involve coordination with multiple trades and equipment types. Pump trucks, concrete buckets, vibrators, finishing tools, and saw-cutting equipment all present hazards that must be addressed in pre-task planning. This AHA must be reviewed with all workers before the first concrete placement and updated whenever placement methods, equipment, or site conditions change.
Disclaimer
This content is provided for general informational and educational purposes only. It is not a substitute for a site-specific Job Safety Analysis conducted by a qualified safety professional familiar with your workplace conditions, equipment, and personnel. OSHA citations, BLS statistics, and hazard controls referenced here may not reflect the most current standards or apply to your specific situation. Always consult current OSHA regulations, manufacturer guidelines, and a competent person before beginning work. Health & Safety Systems LLC assumes no liability for actions taken based on this content.
Definable Feature of Work (DFOW)
Concrete Placement & Finishing
All activities associated with concrete placement including final form preparation, concrete delivery coordination, pump or bucket placement, vibration and consolidation, screeding, bull floating, finishing, curing compound application, form stripping, and saw-cutting of control joints. Excludes formwork construction (separate DFOW) but includes verification of formwork readiness.
Typical Duration: 1-2 days per placement; DFOW spans weeks to months on projects with multiple placements
EM 385-1-1 References
Section 24.A: General Concrete and Masonry Requirements
Establishes requirements for concrete operations including formwork, reinforcement, placement, and curing. Addresses equipment operation, material handling, and worker protection during all phases of concrete work.
Section 24.B: Concrete Placement
Specific requirements for concrete delivery, pumping, bucket placement, and consolidation. Addresses hazards from concrete pump lines, tremie operations, and placement in deep forms or elevated structures.
Section 24.C: Form Stripping and Reshoring
Requirements for form removal including structural adequacy verification, reshoring procedures, and protection of workers below during stripping operations.
Section 06.A: Personal Protective Equipment
PPE requirements including skin protection from cement contact, eye protection from splash, and respiratory protection during cutting, grinding, and finishing operations that generate respirable dust.
Section 05.H: Crystalline Silica Exposure Control
Requirements for controlling respirable crystalline silica exposure per OSHA Table 1 or equivalent exposure assessment. Requires written silica exposure control plan, engineering controls, and medical surveillance for exposed workers.
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Start Free TrialRisk Assessment Code (RAC)
The RAC matrix combines hazard severity and probability to assign a risk level before and after controls are applied. This AHA demonstrates risk reduction from initial to residual conditions.
Initial Risk (Before Controls)
Medium (3)
Severity: Critical | Probability: Occasional
Residual Risk (After Controls)
Low (5)
Severity: Marginal | Probability: Unlikely
Step-by-Step AHA Breakdown
Step 1: Verify formwork and pre-placement inspection
Hazards
- Formwork collapse during placement from inadequate bracing or deteriorated components
- Rebar puncture wounds from exposed vertical reinforcement
- Falls into open forms, trenches, or below-grade placements
Controls
- Competent person inspects formwork, shoring, and bracing immediately before placement to verify structural adequacy
- Cap all exposed vertical rebar with OSHA-compliant impalement protection (rebar caps rated for impact)
- Install guardrails or cover openings where workers could fall 6 feet or more into or around formwork
- Verify embedded items, blockouts, and reinforcement are secure and will not shift during placement
- Document pre-placement inspection on the concrete placement checklist
Step 2: Prepare placement area and establish traffic controls
Hazards
- Struck-by from concrete trucks maneuvering in congested work areas
- Workers caught between concrete truck and fixed objects during backing
- Overhead hazard from concrete pump boom swing
Controls
- Designate concrete truck approach routes and staging areas; post traffic control signs
- Assign a spotter for all concrete truck backing operations; no backing without visual guide
- Establish exclusion zone under the concrete pump boom; no personnel within swing radius during boom positioning
- Coordinate delivery schedule to avoid congestion at the placement area
- Verify pump truck outriggers are fully deployed on stable ground before boom deployment
Step 3: Set up concrete pump and placement equipment
Hazards
- Pump line failure from blocked lines or excessive pressure
- Electrocution from pump boom contact with overhead power lines
- High-pressure concrete release during line connection or disconnection
- Musculoskeletal injury from handling heavy pump hose and fittings
Controls
- Inspect pump lines, clamps, and connections before use; replace worn or damaged components
- Maintain minimum 20-foot clearance between pump boom and overhead power lines
- Depressurize pump lines before disconnecting or reconnecting hose sections
- Use two workers to handle pump hose; never direct the end of a pressurized hose at any person
- Secure pump hose at bends and direction changes to prevent whipping if a clamp fails
- Operator maintains visual or radio contact with the placement crew at all times
Step 4: Don PPE for concrete contact
Hazards
- Chemical burns from prolonged wet cement contact with skin (Portland cement is pH 12-13)
- Eye injury from concrete splash
- Dermatitis and cement allergy from repeated unprotected exposure
Controls
- Wear waterproof boots (rubber boots minimum 8 inches high; knee-high preferred for slab work)
- Wear alkali-resistant gloves that extend above the wrist; change gloves if cement gets inside
- Wear long-sleeved shirt and long pants; tuck pants into boots to prevent cement from entering
- Wear safety glasses with side shields or chemical splash goggles
- Have clean water and pH-neutral soap available at the placement area for immediate skin washing
- Wash any cement contact from skin immediately; do not wait for the end of the shift
Step 5: Place and consolidate concrete
Hazards
- Formwork blowout from excessive placement rate or vibrator over-consolidation
- Workers trapped by sudden concrete flow if forms fail
- Electrical shock from vibrator motor or cord damage in wet conditions
- Musculoskeletal strain from operating vibrators, screeding, and handling heavy materials
- Noise exposure from vibrators and pump equipment
Controls
- Place concrete at rates consistent with formwork design pressure; competent person monitors forms during placement
- Do not over-vibrate; insert vibrator vertically and withdraw slowly to avoid aggregate segregation and excess lateral pressure
- Use GFCI-protected power for all electric vibrators and tools; inspect cords before use
- Rotate workers on vibrator and screeding tasks to reduce fatigue and repetitive strain
- Wear hearing protection; concrete vibrators typically generate 90-100 dBA
- Keep workers clear of the area directly below elevated placements where concrete could fall through forms
Step 6: Finish concrete surface
Hazards
- Ergonomic strain from prolonged kneeling, bending, and reaching during hand finishing
- Chemical burns from kneeling in wet concrete without protection
- Slip hazard on wet concrete surfaces
- Heat stress during exterior placements in warm weather
Controls
- Use knee boards to distribute weight and avoid direct concrete contact when hand finishing
- Provide knee pads rated for wet/chemical contact
- Use long-handled tools (bull float, fresno) to minimize bending and reaching
- Schedule rest breaks and provide shade/cooling for hot weather placements
- Maintain clean walkways and access paths around the placement area
Step 7: Apply curing compound and saw-cut control joints
Hazards
- Respiratory exposure to curing compound vapors (solvent-based compounds)
- Respirable crystalline silica exposure during saw-cutting
- Noise exposure from concrete saws (100+ dBA)
- Blade contact laceration from concrete saw
- Slip hazard from curing compound overspray
Controls
- Use water-based curing compounds when possible; if solvent-based, wear organic vapor respirator and ensure ventilation
- Use wet-cutting method for all concrete saw-cutting to suppress silica dust per OSHA Table 1
- Provide continuous water supply to the saw blade; verify water flow before starting each cut
- Wear hearing protection (NRR 25+ for concrete saw operation)
- Operator wears cut-resistant gloves, face shield, and safety glasses during saw-cutting
- Barricade saw-cutting area to protect other workers from noise and slurry spray
Step 8: Strip forms and clean up
Hazards
- Struck-by from falling form panels, wales, or hardware during stripping
- Premature form removal leading to structural failure of green concrete
- Nail and fastener punctures from stripped formwork
- Manual handling injuries from heavy form panels
Controls
- Competent person verifies concrete has reached required strength before authorizing form stripping (cylinder breaks or maturity method)
- Strip forms from top down; do not pry from the bottom where upper panels could fall
- Stack stripped form panels immediately; remove or bend down protruding nails and fasteners
- Use mechanical lifting for form panels exceeding 50 pounds
- Barricade the area below elevated form stripping; do not allow workers to stand under stripping operations
- Install reshoring as specified in the shoring/reshoring plan before removing original shores in multi-story structures
Competent & Qualified Persons
EM 385-1-1 requires designated competent and qualified persons for specific activities. These individuals must have the training, experience, and authority to identify hazards and take corrective action.
Concrete Operations Competent Person
Designated in writing by the contractor. Responsible for inspecting formwork and shoring before placement, monitoring form pressures during placement, authorizing form stripping based on strength verification, and ensuring compliance with the AHA controls. Must have knowledge of concrete construction methods, formwork design loads, and placement procedures.
EM 385-1-1 Reference: Section EM 385-1-1 Section 24.A
Silica Competent Person
Responsible for implementing the written silica exposure control plan. Must be able to identify silica-generating tasks, verify engineering controls (wet methods, LEV) are functioning, ensure proper respiratory protection is used, and oversee exposure monitoring when required.
EM 385-1-1 Reference: Section EM 385-1-1 Section 05.H
Fall Protection Competent Person
Required when concrete placement involves work at heights above 6 feet, including elevated slabs, walls, and columns. Must be able to identify fall hazards, select appropriate fall protection systems, and train workers in their use.
EM 385-1-1 Reference: Section EM 385-1-1 Section 21.C
Equipment, Training & Inspection Requirements
Required Equipment
Training Requirements
- OSHA 30-Hour Construction Safety (required for supervisors on USACE projects)
- Site-specific safety orientation per EM 385-1-1 Section 01.A.13
- Silica awareness training per 29 CFR 1926.1153(i) for all workers exposed to silica-generating tasks
- Concrete placement safety training covering chemical hazards of Portland cement, formwork awareness, and equipment operation
- Concrete pump operator training (manufacturer-specific)
- Fall protection training for workers performing elevated concrete placement
- GHS/Hazard Communication training for cement, curing compounds, form release agents, and admixtures
- Manual material handling and ergonomic awareness training
- Concrete saw operation training (equipment-specific)
Inspection Requirements
- Pre-placement inspection of all formwork, shoring, bracing, and reinforcement by competent person
- Daily inspection of concrete pump, hose connections, clamps, and safety devices
- Pre-use inspection of all electrical tools and GFCI protection
- Verification of concrete saw water supply and blade condition before each cutting session
- Monitoring of formwork during placement for deflection, leakage, or distress
- Concrete strength verification (cylinder breaks or maturity meter) before form stripping
- Weekly documented safety inspection of concrete operations by site safety representative
- Silica exposure monitoring per written exposure control plan (initial and periodic)
Applicable OSHA Standards
29 CFR 1926.701
General Requirements - Concrete and Masonry Construction
Requires protruding reinforcing steel to be guarded to eliminate impalement hazards. Establishes general safety requirements for concrete construction operations.
29 CFR 1926.702
Requirements for Equipment and Tools
Safety requirements for concrete equipment including mixers, power trowels, concrete buggies, pumping systems, concrete buckets, and bull floats. Addresses guarding, operation, and maintenance.
29 CFR 1926.703
Requirements for Cast-in-Place Concrete
Formwork design, shoring, and reshoring requirements. Formwork must be designed, fabricated, erected, supported, braced, and maintained to support all vertical and lateral loads without failure.
29 CFR 1926.1153
Respirable Crystalline Silica
Establishes PEL of 50 ug/m3 TWA for respirable crystalline silica. Table 1 specifies engineering controls and work practices for common construction tasks including concrete saw-cutting (wet method required). Requires written exposure control plan, medical surveillance, and training.
29 CFR 1926.95
Criteria for Personal Protective Equipment
Requires hazard assessment to determine PPE needed. For concrete work, this includes chemical-resistant gloves and boots for cement contact, eye/face protection from splash, and respiratory protection for dust-generating activities.
Required Personal Protective Equipment
Frequently Asked Questions
What EM 385-1-1 sections apply to concrete placement?
The primary sections are 24.A (General Concrete and Masonry Requirements), 24.B (Concrete Placement), and 24.C (Form Stripping and Reshoring). Additional applicable sections include 05.H (Crystalline Silica Exposure Control), 06.A (PPE), 21.C (Fall Protection) for elevated placements, and 16.A-16.H (Cranes) if concrete buckets are crane-placed. The AHA should reference all applicable sections based on the specific placement method and site conditions.
How is silica exposure controlled during concrete saw-cutting?
OSHA Table 1 under 29 CFR 1926.1153 specifies that stationary concrete saws must use integrated water delivery to the blade. Handheld saws must also use continuous water to the blade. The water suppresses respirable dust at the point of generation, which is far more effective than respiratory protection alone. When wet cutting is not feasible, contractors must perform exposure assessment per 29 CFR 1926.1153(d) and implement controls to maintain exposure below the PEL of 50 ug/m3 TWA.
What concrete strength is required before stripping forms?
EM 385-1-1 does not specify a universal strength threshold for form stripping because requirements vary by structural element and loading conditions. The project structural engineer specifies minimum stripping strength in the project specifications, typically 70-75% of design strength for vertical forms and higher for slabs and beams that must support self-weight and construction loads. Strength is verified by testing field-cured cylinders or using maturity meters. A competent person must authorize form removal based on documented strength results.
What causes concrete burns and how are they prevented?
Portland cement mixed with water creates a highly alkaline solution (pH 12-13) that causes chemical burns on prolonged skin contact. The reaction is not immediate, which means workers often do not notice the exposure until tissue damage has already occurred. Burns are most common on the knees, ankles, and hands from kneeling or standing in wet concrete. Prevention requires waterproof boots, alkali-resistant gloves, long pants tucked into boots, and immediate washing of any skin that contacts wet concrete. Clean water and pH-neutral soap must be available at the placement area.
Is a critical lift plan required for concrete bucket placement by crane?
A concrete bucket filled with concrete is a heavy, dynamic load that swings and shifts as concrete flows out of the bucket. While not automatically a critical lift, it becomes one if the loaded bucket weight approaches 75% of the crane rated capacity at the working radius, if the bucket passes over occupied areas, or if site conditions create elevated risk. Even routine concrete bucket lifts require pre-lift planning, qualified rigger attachment, and signal person coordination. Many USACE safety offices treat concrete bucket lifts as critical due to the dynamic load characteristics.