Formwork Erection and Stripping — Safe Work Method Statement
Safe Work Method Statement for the erection, use, and stripping of formwork and falsework systems for concrete structures, addressing falls from height, structural collapse, and manual handling risks in accordance with AS 3610 and Australian WHS Regulations.
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Formwork erection and stripping is explicitly classified as High Risk Construction Work under the model WHS Regulations (Regulation 291, Schedule 3) as "work involving the use of explosives" — and separately through the falls from height category wherever elevated formwork platforms are involved. More directly, the WHS Regulations specifically list "the erection or dismantling of formwork or falsework" in the HRCW list for certain configurations. A SWMS is mandatory before formwork work commences on any construction site.
The formwork system — the combined assembly of form panels, falsework props, frames, and horizontal members — must be designed by a structural engineer or an experienced formwork engineer where the system supports significant concrete loads. AS 3610 (Formwork for concrete) is the key Australian Standard and specifies design loads, deflection limits, camber requirements, and the responsibilities of the formwork designer, erector, and user. The design must account for the wet concrete pressure on vertical forms (which can exceed 50 kPa for fast pour rates), the self-weight and construction live loads on horizontal slab forms, and wind loads on the incomplete assembly. The engineer's design documents must be on site and available to the formwork crew throughout the erection process.
Premature stripping of formwork — removing props before the concrete has gained sufficient strength — has caused multiple progressive slab collapses in Australia. Stripping must not commence until concrete core test results confirm the required stripping strength has been achieved, or until the specified minimum curing period has elapsed. The stripping sequence must be engineered to avoid inducing loads that the partially cured concrete cannot sustain.
The primary fall risks are from working on elevated slab forms and from falling through incomplete deck areas. Guardrails at all open edges and covers over slab penetrations are mandatory controls. Falls during prop stripping — when workers are below the formwork striking it from beneath — require hard hats and controlled work zones.
Customise this template with the specific formwork system type and supplier, the engineer's design reference, the concrete specification and stripping strength requirement, the maximum pour rate, and the fall prevention controls for the specific platform configuration.
Personal Protective Equipment
High Risk Construction Work Types
- •Work involving risk of a person falling more than 2 metres
- •Work involving the use of explosive-powered tools
- •Formwork or falsework
Risk Assessment
1.Falsework and Shoring Setup
| Hazard / Risk | Initial Risk | Control Measures | Residual Risk | Responsibility |
|---|---|---|---|---|
| Collapse of falsework under concrete load | Catastrophic | Formwork and falsework must be designed by a Registered Professional Engineer of Australia (RPEA) prior to erection. Verify that the design documentation, including load calculations and erection drawings, is available on site before work commences. During erection, foreman cross-checks each component placement against the engineering drawing at every level. Conduct a formal pre-pour inspection with sign-off by the engineer or nominated inspector confirming shoring heights, base plate bearing, and cross-bracing are per design. Do not proceed to pour without written sign-off. | Low | Formwork Supervisor / RPEA |
| Injury from component striking workers during erection | High | Establish an exclusion zone beneath the active erection area using bunting or barriers. Workers below the erection level must not stand under panels or props being positioned. All formwork components to be lifted by crane must be rigged by a licensed dogman. Workers not directly involved in rigging must stand clear of the swing radius. Use tag lines to control panels during crane placement. | Low | Crane Operator / Dogman / Site Supervisor |
2.Erecting Deck Formwork at Height
| Hazard / Risk | Initial Risk | Control Measures | Residual Risk | Responsibility |
|---|---|---|---|---|
| Falls from unprotected formwork edges | Catastrophic | Install edge protection (top rail at 900 mm minimum, mid rail, and kickboard) on all open edges of formwork decking before workers are permitted to work adjacent to the edge. Where edge protection cannot be installed before access is required, workers must wear a full-body harness attached to a temporary horizontal lifeline or static anchor rated to AS/NZS 1891.4, positioned to limit fall distance to less than 600 mm to any lower surface. Conduct daily inspection of edge protection and document findings in the site safety register. | Moderate | Formwork Supervisor / All Workers |
| Falls through incomplete decking sections | Catastrophic | Never leave incomplete deck sections unprotected. Fit a 'DANGER — INCOMPLETE DECK' sign and physically barricade any open area immediately when work is paused. Ensure decking panels are secured against wind uplift and accidental displacement using formwork clips or ties per manufacturer's instructions. Conduct a pre-shift inspection of all deck sections to confirm completeness before workers are allowed on the deck. | Moderate | Formwork Supervisor / Shift Supervisor |
3.Pre-Pour Inspection
| Hazard / Risk | Initial Risk | Control Measures | Residual Risk | Responsibility |
|---|---|---|---|---|
| Structural deficiency or missing components not identified before pour | Catastrophic | Conduct a formal hold-point pre-pour inspection using a documented checklist covering: all shoring plumb and at design spacing, all base plates on firm bearing, all ties and wedges in place and tight, edge protection complete, safe access maintained, and no unauthorised modifications. Inspection must be signed off by the site supervisor and the formwork engineer or their nominated representative. Concrete pour must not commence until written clearance is issued. | Low | Formwork Engineer / Site Supervisor |
4.Concrete Pour on Formwork
| Hazard / Risk | Initial Risk | Control Measures | Residual Risk | Responsibility |
|---|---|---|---|---|
| Blowout or formwork failure during pour from excessive concrete pressure | Catastrophic | Coordinate with the concrete supplier to confirm design pour rate does not exceed the rate assumed in the formwork design. Concrete must be placed in layers not exceeding 300 mm and spread across the full deck before the next layer is placed — never dump the full load in one location. Deploy formwork monitors (vibration sensors or visual inspectors) to watch for bulging or movement during the pour. Establish an emergency stop signal and ensure all workers know to move to a safe area immediately if the signal is given. | Moderate | Formwork Supervisor / Concrete Foreman |
5.Formwork Stripping
| Hazard / Risk | Initial Risk | Control Measures | Residual Risk | Responsibility |
|---|---|---|---|---|
| Premature stripping before concrete reaches design strength | Catastrophic | Do not strip any formwork until concrete has achieved the minimum specified compressive strength (typically 75% of f'c or as directed by the engineer). Confirm strength via field-cured test cylinders tested by a NATA-accredited laboratory, or via maturity monitoring where permitted by the design engineer. Stripping authority must be given in writing by the engineer. Remove props from the outermost point inward, never from a central support outward. Workers must not stand directly below any suspended panel being lowered. | Low | Site Engineer / Formwork Supervisor |
| Manual handling injuries during panel removal | Moderate | Use mechanical assists (crane, forklift, form stripping jacks) for panels exceeding 25 kg. For panels below 25 kg, two-person lift is required. Workers are briefed on correct lifting technique: back straight, knees bent, load close to body. Wear cut-resistant gloves when handling rough timber formwork edges. Stack stripped panels in a stable designated laydown area — no stacking above 1.5 m height without restraint. | Low | All 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.