Concrete Saw Cutting — Demolition — Safe Work Method Statement
Safe Work Method Statement for concrete cutting and saw cutting operations during demolition works, including floor saw cutting, wall saw cutting, and core drilling activities on construction sites.
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Concrete saw cutting during demolition works combines the hazards of demolition — structural unpredictability, hazardous materials, and falling debris — with the specific risks of concrete cutting equipment and high-level RCS generation. This work is HRCW under Schedule 3 of the model WHS Regulations both as demolition of structural elements and, in many cases, because it is associated with falls risk or the use of registered plant. A SWMS is mandatory before the work commences.
The silica dust hazard from concrete saw cutting is among the most significant in the construction industry. Dry cutting of concrete without suppression or on-tool extraction produces airborne RCS concentrations that can exceed the 0.05 mg/m³ WES (8-hour TWA) within seconds of starting. Wet cutting — a continuous water supply to the blade during all cutting operations — is the primary engineering control and is mandatory unless technically impracticable. Where wet cutting cannot be used, on-tool dust extraction connected to an H-class vacuum (compliant with AS/NZS 60335.2.69) must be provided. Respiratory protection (minimum P2) is a last resort and a supplement, not a substitute for engineering controls.
Before any cutting is performed on a concrete element during demolition, a structural engineer must assess and approve the cutting locations. Cutting through post-tensioned tendons will cause catastrophic sudden release — the tendons in a PT slab are under loads of 100–200 kN each, and uncontrolled release can project the tendon or slab section with lethal force. Ground-penetrating radar (GPR) scanning to locate PT cables, reinforcement, and embedded services must precede cutting on any suspected PT element.
Vibration from floor saws and wall saws must be assessed against HAV (hand-arm vibration) exposure limits — extended use of floor saws in particular can exceed the daily exposure action value of 2.5 m/s² A(8) if used for long periods without rotation.
Customise this template with the cutting locations and structural engineer's approval, the GPR scan results, the wet suppression or extraction setup, the air monitoring schedule, and the structural support or propping in place at the cutting face. This SWMS applies across all Australian jurisdictions.
Personal Protective Equipment
High Risk Construction Work Types
- •Work involving energised electrical installations
- •Demolition of load-bearing elements
Risk Assessment
1.Pre-cutting services identification and marking
| Hazard / Risk | Initial Risk | Control Measures | Residual Risk | Responsibility |
|---|---|---|---|---|
| Cutting into live embedded electrical, hydraulic, or gas services | Catastrophic | Before any cutting, scan the full cut line with a calibrated GPR (ground penetrating radar) scanner or service detection tool to identify embedded services. Mark all detected services on the surface in paint. Obtain DBYD response and as-built drawings from the building owner. Engage a licensed electrician to de-energise and lock out all electrical circuits in the cut zone. Where services cannot be positively identified or isolated, do not cut — obtain engineer's written instruction before proceeding. | Moderate | Site Manager / Licensed Electrician |
| Cutting into post-tensioned or stressed concrete causing violent failure | Catastrophic | Review structural drawings and confirm with structural engineer whether the concrete contains post-tensioned tendons before any cutting. If post-tensioned tendons are present, engage a specialist post-tensioned concrete contractor to develop a safe cut plan — do not cut post-tensioned concrete without a specific engineering method statement. Mark tendon locations on the slab surface and maintain minimum 100 mm clearance from all tendons. | Moderate | Structural Engineer / Specialist Contractor |
2.Floor saw cutting operations
| Hazard / Risk | Initial Risk | Control Measures | Residual Risk | Responsibility |
|---|---|---|---|---|
| Operator silica dust exposure during floor sawing | Catastrophic | Use only wet-cutting floor saws with a continuous water feed to the blade — maintain water flow at all times during cutting. If wet cutting is not possible (e.g., near live services), use on-tool extraction with HEPA-filtered vacuum and enclose the saw body with a fitted dust shroud. All operators and workers within 6 m to wear P2 respirators. Conduct air monitoring for tasks exceeding 2 hours per day. Rotate operators at 30-minute intervals. Clean up slurry by wet vacuuming — never dry sweep. | Moderate | Operator / Site Supervisor / HSE Manager |
| Floor saw blade kickback or blade breakage | High | Use only diamond blades rated for the material and cut depth. Inspect blade for cracks, missing segments, or warping before each use — replace immediately if any defect is found. Do not force the saw or exceed the manufacturer's recommended cut depth per pass. Make progressive depth cuts in multiple passes rather than single deep cuts. Keep bystanders outside a 6 m radius exclusion zone during cutting. Operator to stand to the side of the blade travel path — never directly behind. | Low | Operator |
3.Wall saw and ring saw cutting
| Hazard / Risk | Initial Risk | Control Measures | Residual Risk | Responsibility |
|---|---|---|---|---|
| Saw or cut section falling causing crush injury | High | Calculate the weight of all cut concrete sections before commencing. Attach rated lifting equipment (chain slings, shackles) or mechanical support (acrow props, hydraulic jacks) to the section before completing the final cut — the section must be supported before it becomes free. Use a crane or certified lifting equipment to lower large sections in a controlled manner. Establish an exclusion zone below and within the fall zone of the cut section during and after cutting. | Low | Operator / Dogman / Supervisor |
4.Core drilling operations
| Hazard / Risk | Initial Risk | Control Measures | Residual Risk | Responsibility |
|---|---|---|---|---|
| Core drill bit seizing and torque reaction injuring operator | High | Always mount core drills to a rated drill stand bolted or vacuum-fixed to the work surface — never hand-hold a core drill over 50 mm diameter. Inspect anchor bolts and vacuum pad grip before commencing. Drill at the manufacturer's recommended speed and water feed for the core diameter. Keep hands away from the rotating barrel at all times. If the drill bit seizes, stop the drill motor immediately — do not attempt to free a seized bit with the motor running. | Low | Operator |
| Water and slurry creating slip hazard on floor | Moderate | Position vacuum slurry collection ring around the drill entry point before drilling. Use a wet/dry vacuum to remove slurry continuously during drilling. Lay non-slip matting around the work area. Post wet floor warning signs beyond the work area. Remove slurry immediately after drilling — do not leave slurry pooled on the floor. Ensure floor drainage path is clear for wet cutting operations. | Low | Operator / Supervisor |
5.Post-cut cleanup and waste management
| Hazard / Risk | Initial Risk | Control Measures | Residual Risk | Responsibility |
|---|---|---|---|---|
| Silica exposure during cleanup of cutting slurry and debris | High | Collect all cutting slurry and debris by wet vacuuming — never use compressed air or dry sweeping to clean up concrete dust or slurry. Dispose of concrete slurry as liquid concrete waste per the environmental protection requirements of the relevant state. Workers handling wet slurry to wear waterproof gloves and boots — concrete is alkaline and causes chemical burns on prolonged skin contact. Decontaminate all PPE before leaving the site. | Low | Workers / 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.