Concrete Grinding and Polishing — Safe Work Method Statement
Safe Work Method Statement for concrete floor grinding, honing and polishing, coating removal and surface preparation using planetary floor grinders and hand-held edge grinders, with controls for silica dust, slurry, noise and electrical leads.
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Concrete grinding and polishing covers mechanical polishing and honing of new slabs, grind-and-seal finishes, removal of old coatings, glues and toppings, and surface preparation before epoxy or other floor coatings go down. Grinding is not High Risk Construction Work in itself, so a SWMS is only legally required where an HRCW trigger applies, such as grinding near an unprotected edge with a fall of more than 2 metres or in an area where powered mobile plant is moving. In practice most principal contractors ask for one on every grinding job, and your duties for crystalline silica under the WHS Regulations apply whether or not a SWMS is required.
The main hazard is respirable crystalline silica (RCS). The sand and aggregate in concrete contain a high proportion of crystalline silica, and dry grinding without capture produces dust far above the workplace exposure standard of 0.05 mg/m³ (8-hour TWA). Edge and corner work with hand-held grinders usually creates more dust than the main floor machine. Every grinder must run either wet or with on-tool extraction connected to an H-class vacuum sized for that machine, and dry sweeping and compressed-air cleaning are out. Wet grinding swaps dust for slurry, which brings slips, electrical risk around leads, and an environmental duty to keep it out of drains. Floor grinders are loud, commonly above 95 dB(A), and edge grinders transmit a lot of hand-arm vibration.
On refurbishment jobs, find out what is on the floor before you grind it. In older buildings, black bitumen-based floor adhesives and vinyl floor tiles may contain asbestos, and old paints and floor coatings may contain lead. Densifiers, grouts, stain guards and solvent-based sealers each bring their own chemical and fire hazards, so check the SDS before use.
No licence is needed to grind concrete, but operators must be trained on the specific machine and vacuum. Tight-fitting respirators must be fit tested, and anyone with regular RCS exposure must be included in health monitoring. Leads must be tested and tagged and protected by an RCD, and three-phase connections should be made by a competent person.
Customise this template with: the building, floor area and slab age; the grinding method (wet or dry with extraction) and machine and vacuum models; any asbestos register or lead test results for existing coatings; the respirator type and fit test records; how the work area is isolated from other trades; the power supply arrangement; the chemical products to be applied; and how slurry and dust waste will be disposed of.
Personal Protective Equipment
Risk Assessment
1.Pre-start floor assessment and area isolation
| Hazard / Risk | Initial Risk | Control Measures | Residual Risk | Responsibility |
|---|---|---|---|---|
| Grinding through existing adhesives, tiles or coatings that contain asbestos or lead | Catastrophic | Before quoting and again before start, check the asbestos register for any building built before 1990 and identify all existing floor coverings, glues and coatings. Treat black bitumen-based adhesives and old vinyl tiles as asbestos-containing until tested. Test old paints and coatings for lead. If asbestos is confirmed, stop: removal must be done by a suitably licensed asbestos removalist before grinding. If lead is present, use wet methods and H-class extraction and follow a lead management plan. | Low | Supervisor / Principal Contractor |
| Other trades and occupants exposed to silica dust and noise | High | Isolate the work area with barricades and signage before grinding starts. Seal doorways and openings to occupied areas with plastic sheeting. Agree work times with the principal contractor or building manager so no other trades work in the same space during grinding. Switch off or seal HVAC returns serving the area. Keep the exclusion zone in place until the floor has been vacuumed clean. | Low | Supervisor |
| Falls through floor penetrations or from slab edges on suspended floors | High | Walk the floor before setting up. Confirm all penetrations are covered with secured, load-rated covers marked as such and that slab edges have edge protection in place. Do not remove covers or edge protection to grind under them; arrange with the principal contractor for an approved method. Grinders must not be operated within 2 metres of an unprotected edge. | Low | Supervisor / Operator |
2.Unloading machines and setting up power
| Hazard / Risk | Initial Risk | Control Measures | Residual Risk | Responsibility |
|---|---|---|---|---|
| Crush or strain injury unloading heavy planetary grinders | High | Unload grinders and weights using the vehicle tailgate lift, a rated ramp or a forklift, never by manual lift. Remove grinding weights and heads before moving the machine. Use two workers to guide machines on ramps and keep feet clear of wheels. Check the machine weight and the floor and lift ratings when moving between levels. Use a trolley for diamond tooling cases and vacuum units. | Low | Operator |
| Electric shock from damaged leads or connections in wet or dusty conditions | Catastrophic | All leads, plugs and machines must be tested and tagged at the interval set for construction work and inspected visually before each shift. Connect only to a supply protected by an RCD. Three-phase connections and any generator set-up must be checked by a competent person. Keep leads off the floor where possible using lead stands or hooks. Never run leads through slurry. Remove any damaged lead from service immediately. | Low | Operator / Supervisor |
3.Floor grinding with ride-on or walk-behind machines
| Hazard / Risk | Initial Risk | Control Measures | Residual Risk | Responsibility |
|---|---|---|---|---|
| Inhalation of respirable crystalline silica | Catastrophic | Run every dry grinder connected to an H-class vacuum rated for that machine, with the shroud skirt intact and sitting on the floor. Check the vacuum airflow indicator and pre-separator before each start and every time tooling is changed. Stop grinding if visible dust escapes the shroud. Operators and anyone in the zone wear a fit-tested P2 respirator as a minimum. Arrange air monitoring for jobs running several days to confirm exposures stay below the workplace exposure standard. | Moderate | Operator / Supervisor |
| Noise-induced hearing loss | High | Treat the grinding area as a hearing protection zone and signpost it. Operators and anyone within the zone wear Class 5 hearing protection. Locate vacuum units outside the main area where hoses allow. Rotate operators on long shifts. Include regular grinder operators in audiometric testing. | Low | Operator / Supervisor |
| Struck by flying diamond segments or debris | Moderate | Inspect tooling before fitting and replace any tooling with cracked or missing segments. Fit tooling only with the machine isolated at the plug. Check the floor for protruding bolts, fixings and rebar ends and remove them before grinding. Keep others outside the barricaded zone. Safety glasses are worn at all times. | Low | Operator |
4.Edge and detail grinding with hand-held grinders
| Hazard / Risk | Initial Risk | Control Measures | Residual Risk | Responsibility |
|---|---|---|---|---|
| High dust exposure from edge grinding close to the operator's breathing zone | Catastrophic | Use edge grinders only with a dust shroud connected to an H-class vacuum. Never edge grind dry without extraction. Operators wear a P3 respirator or PAPR for edge work. Keep the shroud flat to the surface. Work with the vacuum hose positioned so the operator's face is not over the cutting area. | Moderate | Operator |
| Hand-arm vibration and kickback from hand grinders | High | Use grinders with anti-vibration handles and keep both hands on the tool. Limit continuous edge grinding to 30-minute blocks, then rotate to another task. Wear anti-vibration gloves. Let the grinder stop fully before setting it down. Do not use a cup wheel at a higher speed than its rating. | Low | Operator |
5.Wet grinding and slurry management
| Hazard / Risk | Initial Risk | Control Measures | Residual Risk | Responsibility |
|---|---|---|---|---|
| Slips on slurry and electrical risk from leads in water | High | Use only machines designed for wet grinding. Keep leads raised and clear of the slurry path. Recover slurry continuously with a wet vacuum or squeegee to a collection point. Wear rubber boots with slip-resistant soles. Signpost the wet area and keep others out. | Low | Operator |
| Slurry entering stormwater or drying to dust | Moderate | Block floor wastes and drains in the work area before starting. Collect slurry in drums or a settling container and dispose of it as directed by local council requirements. Do not wash slurry off the slab into gardens or drains. Collect slurry before it dries; once dry, treat the residue as silica dust. | Low | Operator / Supervisor |
6.Applying densifiers, grouts, stains and sealers
| Hazard / Risk | Initial Risk | Control Measures | Residual Risk | Responsibility |
|---|---|---|---|---|
| Skin and eye burns from alkaline densifiers or acid stains | Moderate | Read the SDS before use. Decant products into labelled containers. Apply with low-pressure sprayers or microfibre applicators. Wear chemical-resistant gloves and goggles. Keep clean water and an eyewash on site. Do not mix products unless the manufacturer allows it. | Low | Operator |
| Fire or vapour exposure from solvent-based sealers in enclosed areas | High | Prefer water-based sealers. Where solvent-based products are used, ventilate the area mechanically, remove ignition sources including running petrol plant and pilot lights, and wear a respirator with organic vapour filters as specified on the SDS. Keep a suitable fire extinguisher at the work area. Store solvents outside the work area in a ventilated location. | Low | Operator / Supervisor |
7.Clean-up and emptying vacuums
| Hazard / Risk | Initial Risk | Control Measures | Residual Risk | Responsibility |
|---|---|---|---|---|
| Dust release when emptying vacuum collectors and changing filters | High | Use vacuums with continuous bagging or sealed collection bags. Empty and bag waste outside or in a ventilated area, never inside the finished space. Wear a P2 respirator during emptying and filter changes. Seal bags before removing them from the vacuum and dispose of them as directed by the waste contractor. Clean the floor and equipment with an H-class vacuum, never by dry sweeping or compressed air. | Low | Operator |
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.