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Concrete Core Drilling — Safe Work Method Statement

Safe Work Method Statement for diamond core drilling through concrete slabs, walls and soffits for service penetrations, covering scanning for reinforcement, tendons and embedded services, rig anchoring, wet drilling, core breakthrough and protection of the area below.

Category: Concrete, Masonry & Roofing
HRCW: 1 category
Job steps: 6
Hazards rated: 18
PPE items: 7

Core drilling is High Risk Construction Work whenever the core could pass through energised electrical cables or conduits cast into the slab or wall, which is the case on almost every existing building. A SWMS is required. It is also HRCW where you drill from a scaffold, EWP or ladder with a fall of more than 2 metres, or near a slab edge or open penetration. Add those to the SWMS where they apply. General slab sawing and wall sawing are covered by the concrete cutting template; this one is about the hazards specific to coring.

What is inside the concrete is the first problem. Slabs and walls can hold live cables, water and gas pipes, and on many commercial buildings post-tensioned tendons. Cutting a stressed tendon can release it violently and weaken the slab. Every core position should be approved by the builder or structural engineer and scanned before drilling. Ground penetrating radar is the usual method. Radiography (X-ray) needs a licensed radiography contractor and an exclusion zone, so check your state or territory radiation regulator before using it.

The second problem is what happens on the other side. When the bit breaks through, the core and water drop to the floor below or into a ceiling space, often where other trades or the public are working. Set up an exclusion zone and barricade underneath before you start, put a spotter or sign at the area below, and retain the core where possible. For wall cores, check what is on the far side.

The rig itself can hurt you. If an anchor pulls out or a vacuum base loses suction, the drill can rotate and throw the operator. Handheld drills can wrench wrists and shoulders when the bit binds. Use the anchor type and size the rig manufacturer specifies, test the anchor before drilling, and use a slip clutch on handheld drills. Wet coring keeps silica dust down, but the slurry is alkaline and slippery, and water near an electric motor needs an RCD and a water collection ring, particularly for overhead cores.

Customise this template with the core locations, diameters and depths, the engineer or builder approval reference, the scanning method and results, whether the slab is post-tensioned, the area below and how it will be barricaded, the drill type and anchoring method, how slurry and water will be collected, and the fire-rated sealing that will follow.

High Risk Construction Work Types

Work on or near energised electrical installations or services

Personal Protective Equipment

Safety glasses or face shield
Hearing protection
Steel-capped waterproof safety boots
Waterproof gloves with good grip
P2 respirator (dry coring or where slurry dries)
Hard hat (overhead coring and work below)
Waterproof overalls or apron

Risk Assessment

RatingsCatastrophicHighModerateLow

Step 1Core location approval and scanning

Hazard / Risk	Initial Risk	Control Measures	Residual Risk	Responsibility
Cutting a post-tensioned tendon or main reinforcement	Catastrophic	Confirm whether the slab is post-tensioned from drawings or the builder. Every core location approved in writing by the builder or structural engineer. Scan with GPR and mark tendons and bars on the surface. Relocate cores that clash.	Moderate	Supervisor
Drilling into live cables or conduits	High	Scan each location and mark embedded services. Where services cannot be confirmed clear, have the electrician isolate the circuits before drilling. Never rely on drawings alone.	Low	Supervisor
Radiation exposure during X-ray scanning	High	Radiography only by a licensed radiography contractor. Clear and barricade the exclusion zone they set on all affected levels. Nobody re-enters until they give the all clear.	Low	Radiography Contractor

Step 2Setting up the exclusion zone below and behind

Hazard / Risk	Initial Risk	Control Measures	Residual Risk	Responsibility
Falling core striking a person on the floor below	High	Barricade the area below each core with a radius of at least 2 m and post signs. Check ceiling spaces for workers. A spotter or radio contact with the level below during breakthrough.	Low	Driller
Water and slurry damaging equipment or services below	Moderate	Cover or move equipment below. Fit a water collection ring or catch bag under overhead cores. Tell the building manager before drilling over occupied areas.	Low	Driller
Injury to people on the far side of a wall core	Moderate	Check the far side of the wall and barricade it. For external walls, check for public areas, windows and services outside.	Low	Driller

Step 3Rig set-up and anchoring

Hazard / Risk	Initial Risk	Control Measures	Residual Risk	Responsibility
Rig rotating or tipping if the anchor fails	High	Use the anchor size and type specified by the rig manufacturer. Drill the anchor hole clear of reinforcement, set the anchor fully and test it before coring. For vacuum bases, check the seal on a clean, flat surface and monitor the gauge throughout.	Low	Driller
Back strain lifting rig, motor and bits	Moderate	Carry the motor and column separately. Use a trolley on site. Two-person lift for heavy rigs and large bits.	Low	Driller
Electric shock from a wet electric motor	High	Drill tested and tagged and connected through an RCD (in-line RCD at the drill where supplied). Keep leads and plugs off wet floors. Use a hydraulic or air drill for heavily wet overhead work where available.	Low	Driller

Step 4Wet core drilling

Hazard / Risk	Initial Risk	Control Measures	Residual Risk	Responsibility
Wrist and shoulder injury when the bit binds	High	Rig-mount wherever possible. Handheld drills must have a working slip clutch and side handle. Do not stand in line with the handle. Ease off feed pressure when hitting steel.	Low	Driller
Silica dust from dry coring	High	Wet core as standard. Dry coring only with a dust extraction system fitted to the drill and a P2 respirator. Never let slurry dry and be swept.	Low	Driller
Noise exposure	Moderate	Hearing protection for the operator and anyone within a few metres. Warn nearby trades before starting.	Low	Driller

Step 5Breakthrough and core removal

Hazard / Risk	Initial Risk	Control Measures	Residual Risk	Responsibility
Core dropping uncontrolled through a slab	High	Confirm the area below is clear by radio or spotter just before breakthrough. Use a core retention method where possible. Slow the feed as the bit nears full depth.	Low	Driller
Crush and cut injuries removing cores from the bit	Moderate	Isolate the drill before freeing a stuck core. Use the correct knock-out tool, not hands. Gloves when handling cores, and large cores lifted by two people.	Low	Driller
Fall or trip into the open penetration	Moderate	Cover or barricade the core hole as soon as it is drilled. Covers fixed and marked until sealed by the follow-on trade.	Low	Driller

Step 6Slurry collection and pack-up

Hazard / Risk	Initial Risk	Control Measures	Residual Risk	Responsibility
Slips on wet slurry	Moderate	Wet vacuum slurry as you go. Put out wet floor signs. Clean the area before leaving.	Low	Driller
Skin burns from alkaline slurry	Moderate	Waterproof gloves and long sleeves. Wash skin contact straight away with clean water.	Low	Driller
Slurry entering stormwater drains	Moderate	Collect slurry and dispose of it as directed by the site waste plan. Do not wash it into stormwater.	Low	Driller

Relevant Codes of Practice

Worker Acknowledgement

By signing below, I confirm that I have read, understood and agree to comply with this Safe Work Method Statement.

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