SWMS template · General Construction
Caulking and Sealant Application — Safe Work Method Statement
Safe Work Method Statement for removing old sealant and applying silicone, polyurethane, acrylic and fire-rated sealants to joints in walls, windows, wet areas, floors and facades, covering chemical exposure, sharp tools, repetitive strain and old mastics that may contain asbestos.
- Category
- General Construction
- HRCW
- Not HRCW
- Job steps
- 7
- Hazards rated
- 16
- PPE items
- 6
Caulking and sealant work done at floor level or from a stepladder is not High Risk Construction Work, so a SWMS is not legally required for most jobs. It is still good practice, and principal contractors usually ask for one. The job becomes HRCW when you seal facade, window or expansion joints where you could fall more than 2 metres, such as from an EWP, swing stage, scaffold or rope access. Add that type and the access controls to the SWMS when it applies.
Know your products. Polyurethane and hybrid sealants, primers and some two-part sealants can cause skin and breathing sensitisation, and once you are sensitised even small exposures can trigger a reaction. Some polyurethane products contain isocyanates. Acetoxy (vinegar-smelling) silicones release acetic acid as they cure, which irritates eyes and lungs in small rooms. Solvent-based primers and clean-up solvents are flammable. Read the SDS for each product before starting, wear gloves suited to the chemical, ventilate enclosed rooms, and keep ignition sources away from solvent work.
Removing old sealant is where most cuts happen. Utility knives and oscillating tools slip easily on old, hard sealant. Cut away from your body, use a blade holder, and dispose of blades in a sharps container. Older buildings may have mastics, putties and joint sealants that contain asbestos. Asbestos was banned in Australia from 31 December 2003, but older products are still in place, so test suspect material before removing it on buildings of that age.
Caulking is repetitive. Hours of squeezing a manual gun cause wrist, hand and shoulder strain, so use battery or pneumatic guns for large jobs and rotate tasks. Fire-rated sealants at service penetrations must match the tested system for that wall or floor, so install exactly to the manufacturer's details and record each penetration.
Customise this template with the joints and areas to be sealed, the products and SDS references, any primers and solvents used, the method for removing old sealant, asbestos test results for older buildings, the ventilation arrangements, the access method and any work at height, fire-rated penetration details and records, and how waste sealant, tubes and solvents will be disposed of.
Important: This SWMS template is a starting point only. Review and customise it for your workplace and task. The PCBU remains responsible for ensuring the SWMS is suitable for the work. Not legal advice.
Personal Protective Equipment
- Nitrile or chemical-resistant gloves (to the product SDS)
- Safety glasses
- Cut-resistant gloves (removing old sealant)
- Organic vapour respirator (solvent primers in enclosed areas, as the SDS requires)
- Knee pads
- Steel-capped safety boots (or as required by site rules)
Risk Assessment
RatingsCatastrophicHighModerateLow
Step 1Product selection and SDS review
| Hazard / Risk | Initial Risk | Control Measures | Residual Risk | Responsibility |
|---|---|---|---|---|
| Skin and breathing sensitisation from polyurethane, isocyanate or epoxy products | High | Read the SDS for every sealant and primer before use. Choose lower-hazard products where the joint allows. Gloves suited to the chemical. Workers with a known sensitisation do not use the product. | Low | Supervisor |
| Using the wrong fire-rated product at a penetration | Moderate | Check the fire-rated system for each wall or floor type and service. Use only the tested product and method. Record each penetration as required by the builder. | Low | Supervisor |
Step 2Removing old sealant
| Hazard / Risk | Initial Risk | Control Measures | Residual Risk | Responsibility |
|---|---|---|---|---|
| Cuts from knives and scrapers | High | Use blade holders or retractable knives. Cut away from the body. Cut-resistant gloves on the holding hand. Blades into a sharps container. | Low | Applicator |
| Disturbing asbestos in old mastic or putty | High | On buildings old enough to contain asbestos products, test suspect mastics and putties before removal. If asbestos is found, stop and follow asbestos removal requirements. | Low | Supervisor |
| Hand-arm vibration and flying fragments from oscillating tools | Moderate | Safety glasses. Limit time on the tool and rotate tasks. Keep the free hand away from the blade. | Low | Applicator |
Step 3Cleaning and preparing joints with solvents
| Hazard / Risk | Initial Risk | Control Measures | Residual Risk | Responsibility |
|---|---|---|---|---|
| Fire from flammable solvents and primers | Moderate | No ignition sources in the area. Use small quantities in closed containers. Store rags in a lidded metal bin. | Low | Applicator |
| Inhaling solvent vapour in small rooms | Moderate | Open windows and doors or use a fan to ventilate. Organic vapour respirator where the SDS requires it. | Low | Applicator |
Step 4Fitting backing rod and priming
| Hazard / Risk | Initial Risk | Control Measures | Residual Risk | Responsibility |
|---|---|---|---|---|
| Primer splashing into eyes | Moderate | Safety glasses. Apply primer with a small brush, not by pouring. | Low | Applicator |
| Fall from ladder reaching high joints | Moderate | Use a platform ladder or mobile scaffold. Move the ladder rather than overreaching. Any work with a fall over 2 m to be added to this SWMS as HRCW. | Low | Applicator |
Step 5Applying sealant
| Hazard / Risk | Initial Risk | Control Measures | Residual Risk | Responsibility |
|---|---|---|---|---|
| Wrist, hand and shoulder strain from manual guns | Moderate | Use battery or pneumatic guns for large runs. Use sausage packs where available. Rotate tasks and take short breaks. | Low | Applicator |
| Skin contact with uncured sealant | Moderate | Nitrile gloves. Do not tool joints with bare fingers. Wash hands before eating. | Low | Applicator |
| Knee strain sealing floor joints | Moderate | Knee pads or a kneeling mat. Change position regularly. | Low | Applicator |
Step 6Tooling, finishing and curing
| Hazard / Risk | Initial Risk | Control Measures | Residual Risk | Responsibility |
|---|---|---|---|---|
| Acetic acid vapour from curing silicone in enclosed areas | Moderate | Ventilate wet areas and small rooms during and after application. Use neutral-cure silicone in poorly ventilated spaces. | Low | Applicator |
| Others touching or damaging fresh joints | Low | Tape or sign fresh joints and tell the site supervisor the cure time. | Low | Applicator |
Step 7Clean-up and waste disposal
| Hazard / Risk | Initial Risk | Control Measures | Residual Risk | Responsibility |
|---|---|---|---|---|
| Skin contact with clean-up solvents | Moderate | Chemical-resistant gloves. Use the cleaner the manufacturer specifies. Do not wash hands in solvent. | Low | Applicator |
| Solvent rags and waste igniting or polluting drains | Moderate | Put solvent rags in a lidded metal bin. Dispose of tubes, waste sealant and solvents as directed by the site waste plan, not into drains. | Low | Applicator |
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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