Important: This SWMS template is provided as a starting point only. It must be reviewed and customised to reflect the specific conditions, hazards, and controls for your workplace and task. The PCBU remains responsible for ensuring the SWMS is suitable for the specific work. This template does not constitute legal advice. Refer to your state or territory WHS regulator for compliance requirements.

General Construction

Epoxy Floor Coating — Safe Work Method Statement

Safe Work Method Statement for applying epoxy, polyurethane and polyaspartic floor coatings to garages, warehouses, workshops and commercial floors, including diamond grinding, crack repair, mixing, application and curing.

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Epoxy floor coating becomes High Risk Construction Work when the products or the space create a contaminated or flammable atmosphere. That is common with solvent-based primers, solvent-borne epoxies and polyurethane topcoats applied indoors, in basements, car parks, cool rooms or small garages with poor airflow. Water-based systems applied in a large, open warehouse may not create that atmosphere, in which case a SWMS is not legally required for the coating itself, though the principal contractor will usually want one.

The chemicals are the main long-term hazard. Epoxy resins and amine hardeners are strong skin sensitisers: many coaters develop dermatitis after months of exposure, and once sensitised, they may not be able to keep working with epoxy at all. Polyurethane and some polyaspartic systems contain isocyanates, which can cause occupational asthma. Read the SDS for each component, wear the gloves the SDS specifies (often nitrile, changed often), cover skin and use the respirator cartridge specified. Spraying isocyanate products needs supplied-air respiratory protection.

Surface preparation creates silica dust. Diamond grinding and shot blasting concrete releases respirable crystalline silica, so grinders must have a shroud connected to an H-class vacuum, and operators should wear at least a P2 respirator. Older floors may have asbestos-containing vinyl tiles or adhesive, so check before grinding off old floor finishes. Grinders are also heavy, noisy and vibrate, and the cords run across a floor you are working on.

Flammable vapour needs real control. Remove all ignition sources before mixing, including pilot lights on water heaters in garages, forklifts, grinders and phones in the vapour area. Ventilate with fans rated for the hazard and keep it running through curing. Mixed epoxy generates heat in the bucket and can smoke or ignite if left in a mass, so mix only what you can apply in the pot life and spread leftovers thin to cure.

Customise this template with each product name and SDS reference, the floor area and space volume, ventilation method and air changes, ignition sources removed and who checked, the grinding equipment and vacuum class, asbestos status of any old floor finish, the respirator types, cure times, and how other trades are kept off the floor.

Personal Protective Equipment

Nitrile gloves (to the product SDS, changed often)Chemical splash gogglesHalf-face respirator with organic vapour/particulate cartridgesSupplied-air respirator (spraying isocyanate products)P2 respirator (grinding)Disposable coverallsSpiked shoes (walking on wet coating)Hearing protection (grinding)

High Risk Construction Work Types

•Work in an area that may have a contaminated or flammable atmosphere

Risk Assessment

1.Pre-start: products, space and ignition sources

Hazard / Risk	Initial Risk	Control Measures	Residual Risk	Responsibility
Flammable vapour ignited by pilot lights, motors or sparks	Catastrophic	Identify and isolate every ignition source in and next to the area, including water heater pilots, fridges, forklifts and switching appliances. Post no smoking and no hot work signs. Use non-sparking ventilation fans. Extinguisher at the entry.	Low	Coating Supervisor
Harmful vapour building up in an enclosed space	High	Assess whether the area is a confined space. Provide forced ventilation sized to the space and run it through application and curing. Monitor with a gas detector for solvent products in basements or small rooms.	Moderate	Coating Supervisor

2.Surface preparation: grinding and shot blasting

Hazard / Risk	Initial Risk	Control Measures	Residual Risk	Responsibility
Silica dust from diamond grinding	High	Grinder shroud connected to an H-class vacuum sized for the machine. P2 respirator minimum, PAPR for long grinding shifts. Keep others out of the area. Empty vacuums carefully into sealed bags.	Moderate	Coating Applicator
Asbestos in old vinyl tiles or adhesive	Catastrophic	Test old floor finishes in buildings built before 1990 before grinding. If asbestos is present, removal by a licensed removalist before preparation starts.	Low	Coating Supervisor
Vibration, noise and back strain from heavy grinders	Moderate	Two people to load grinders onto vehicles. Hearing protection. Limit continuous use and rotate operators. Leads routed behind the machine.	Low	Coating Applicator

3.Crack repair and patching

Hazard / Risk	Initial Risk	Control Measures	Residual Risk	Responsibility
Skin contact with epoxy filler	Moderate	Nitrile gloves and long sleeves. Remove contaminated gloves immediately and wash hands. Do not use solvent to clean skin.	Low	Coating Applicator

4.Mixing resin and hardener

Hazard / Risk	Initial Risk	Control Measures	Residual Risk	Responsibility
Skin sensitisation and eye splash from resin and hardener	High	Mix in a designated area on a drop sheet. Goggles, nitrile gloves and coveralls. Keep eyewash on hand. Never touch skin with contaminated gloves.	Low	Coating Applicator
Runaway heat and smoke from mixed epoxy left in the bucket	High	Mix only what can be applied within the pot life. Pour onto the floor promptly. Spread leftovers thin on a sheet outside to cure. Never put a full bucket of mixed product in a bin.	Low	Coating Applicator

5.Applying primer, body coats and topcoats

Hazard / Risk	Initial Risk	Control Measures	Residual Risk	Responsibility
Inhalation of solvent or isocyanate vapour	High	Respirator with the cartridge specified on the SDS, fit-checked before use. Supplied-air respirator for spraying isocyanates. Ventilation running. Rotate workers out of the area for breaks.	Moderate	Coating Applicator
Slips on wet coating	Moderate	Plan the application so you finish at the exit. Spiked shoes for broadcast and self-levelling coats. Keep the area barricaded.	Low	Coating Applicator

6.Curing, clean-up and waste

Hazard / Risk	Initial Risk	Control Measures	Residual Risk	Responsibility
Others entering the area during curing	Moderate	Barricade and sign the area with cure times. Ventilation running through curing. Inform the client and other trades.	Low	Coating Supervisor
Incorrect disposal of resins, solvents and dust	Moderate	Fully cure leftover mixed product before disposal. Solvent rags in a closed metal bin. Grinding dust bagged and disposed of as construction waste. Unmixed product returned or disposed of as liquid chemical waste.	Low	Coating 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.

Name: ___________________Date: ___________________