Concrete Cutting — Safe Work Method Statement
Safe Work Method Statement for concrete cutting operations including slab sawing, core drilling, and wall sawing, with specific controls for crystalline silica dust management in compliance with Australian WHS legislation and the Crystalline Silica Dust Code of Practice.
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Concrete cutting — including flat slab sawing, wall sawing, wire sawing, and core drilling — generates some of the highest concentrations of respirable crystalline silica (RCS) of any construction activity. Normal concrete contains 20–30% crystalline silica by weight, and dry cutting without suppression can produce airborne RCS levels hundreds of times above the workplace exposure standard of 0.05 mg/m³ (8-hour TWA). The Safe Work Australia Code of Practice: Crystalline Silica is the primary reference document for this SWMS.
Concrete cutting work may also be HRCW under Schedule 3 of the model WHS Regulations where it is associated with demolition, structural modification, or creates a risk of structural collapse. In these scenarios a SWMS is legally required. Even where the cutting is not formally classified as HRCW, the silica exposure risk means a SWMS reflecting the code of practice controls is strongly recommended and will be expected by principal contractors.
There is no specific licence required for concrete cutting work, but operators must be trained and competent in the use of the specific equipment — flat saws, wall saws, core drills, and wire saws are all specialised items of plant. Plant must be maintained to manufacturer specifications, and diamond blades must be rated for the cutting method and material. Wet cutting is the primary engineering control for silica — a continuous water supply to the blade that suppresses dust at source is required for all slab and wall sawing. Where wet cutting is not practicable (for example, in live electrical areas), on-tool vacuum extraction using an H-class vacuum compliant with AS/NZS 60335.2.69 must be used instead.
When customising this template, document the specific cutting method and equipment, the concrete substrate type and thickness, the wet suppression or extraction system to be used, the air monitoring program, and the respiratory protection selected. Confirm that cutting will not compromise structural integrity — a structural engineer's approval is required before cutting structural elements or post-tensioned slabs.
This template applies in all Australian jurisdictions. The 0.05 mg/m³ WES for RCS applies nationally, including Western Australia and Victoria.
Personal Protective Equipment
High Risk Construction Work Types
- •Work involving the disturbance of a structure or part of a structure that contains or is likely to contain asbestos
- •Work involving demolition of a structure
- •Work in an area that may have a contaminated or flammable atmosphere
Risk Assessment
1.Pre-work planning and service location
| Hazard / Risk | Initial Risk | Control Measures | Residual Risk | Responsibility |
|---|---|---|---|---|
| Striking buried electrical, gas, water, or hydraulic services during cutting | Catastrophic | Before any cutting commences, obtain and review current as-built drawings for the structure. Conduct a scan of the cutting zone using a calibrated GPR (ground penetrating radar), electromagnetic cable detector, or similar buried service locator. Mark all identified services on the surface using paint or chalk. Establish a minimum no-cut buffer of 150 mm from any identified service. Liaise with the facility manager to identify any services not shown on drawings. If services are suspected but cannot be confirmed, handcut the initial slot before using powered saws. | Moderate | Site Supervisor / Licensed Excavator |
| Asbestos-containing material (ACM) disturbed during concrete cutting | Catastrophic | Before commencing, obtain an asbestos register or asbestos assessment report for the structure. If ACM is identified in or adjacent to the cutting zone, the work must be rescheduled and an appropriately licensed asbestos removalist engaged. Do not proceed if ACM is suspected and cannot be positively excluded. Treat all pre-1990 buildings as presumed to contain asbestos until proven otherwise. If ACM is unexpectedly encountered during cutting, immediately cease operations, isolate the area, and contact the principal contractor and an asbestos assessor. | Low | Site Supervisor / Asbestos Assessor |
2.Concrete saw setup and diamond blade inspection
| Hazard / Risk | Initial Risk | Control Measures | Residual Risk | Responsibility |
|---|---|---|---|---|
| Diamond blade disintegration causing projectile injury | Catastrophic | Inspect the diamond blade before fitment for cracking, missing segments, warping, or damage to the blade core. Verify the blade's maximum RPM rating equals or exceeds the saw's rated speed. Check that the blade is rated for the application (wet cutting, dry cutting, or specified material). Ensure the blade is mounted correctly with the rotation direction arrow aligned, central flange fitted, and arbour nut tightened to the torque specified by the manufacturer. Confirm the blade guard is in place and all locking mechanisms are engaged before powering on. | Moderate | Operator |
3.Wet concrete cutting operations
| Hazard / Risk | Initial Risk | Control Measures | Residual Risk | Responsibility |
|---|---|---|---|---|
| Silica dust inhalation causing silicosis | Catastrophic | Wet cutting is the primary control measure and must be used whenever practicable. Ensure a continuous and adequate water supply (minimum 1 L/min) is maintained to the blade throughout cutting. Do not reduce the water flow to speed up the cut. Monitor the slurry at the blade to confirm water suppression is effective. Where wet cutting is not practicable, connect a HEPA-filtered vacuum extraction system to the blade guard. All workers within the dust exclusion zone must wear a minimum half-face P2 respirator. Prohibit dry sweeping of concrete dust slurry — use wet vacuum or wet mopping. Air quality monitoring is required for prolonged concrete cutting operations to ensure respirable crystalline silica (RCS) levels remain below 0.05 mg/m³ TWA. | Moderate | Operator / Safety Officer |
| Operator fatigue and loss of control from vibration and noise | High | Limit continuous saw operation to 30-minute intervals; rotate operators for cuts exceeding one hour. Use anti-vibration gloves rated to EN ISO 10819 standard. Hearing protection (minimum SLC80 25) is mandatory for all personnel within 5 metres — concrete saws generate 100–115 dB(A). Mark and enforce an exclusion zone around the cutting area. Ensure the saw has a dead-man switch and that the operator maintains a balanced two-handed grip. Do not operate when fatigued. | Low | Operator / Site Supervisor |
4.Core drilling operations
| Hazard / Risk | Initial Risk | Control Measures | Residual Risk | Responsibility |
|---|---|---|---|---|
| Core drill kickback causing shoulder or wrist injury | High | Anchor the core drill rig to the substrate using the manufacturer's approved anchor bolt and base plate system before commencing drilling. Never handheld a core drill larger than 50 mm diameter for vertical drilling. Ensure the rig is levelled and all locking handles are fully tightened. Check that the core barrel is not bent or damaged. Apply consistent downward feed pressure — do not force the drill. If the drill stalls or binds, release feed pressure before attempting to free it. Wear anti-vibration gloves for prolonged drilling. | Low | Operator |
5.Cleanup and slurry disposal
| Hazard / Risk | Initial Risk | Control Measures | Residual Risk | Responsibility |
|---|---|---|---|---|
| Environmental contamination and slip hazard from concrete slurry | Moderate | Contain concrete cutting slurry using a containment bund or vacuum recovery system. Do not allow slurry to enter drains, waterways, or stormwater systems — this is an environmental regulatory requirement. Collect slurry using a wet vacuum and dispose of in accordance with local council waste requirements. Apply wet-floor warning signs immediately. Once slurry is collected, clean residual dust using a HEPA vacuum — never dry sweep. Ensure all workers wear non-slip footwear in the work area while slurry is present. | Low | Operator / Site Supervisor |
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.