Reclamation Safety and Health Standards

January 2023 Section 25: Concrete, Masonry, and Formwork

Section 25
Concrete, Masonry, and Formwork

25.1 Scope
This section establishes safety requirements for concrete, masonry construction, and formwork.
Additionally, this section outlines safety as it relates to the topics of concrete conveyance,
formwork and falsework, shoring, precast concrete, and masonry work. Civil flatwork concrete
(unless used as a foundation) does not need to adhere to the professional engineering design
requirements contained in this section, but is subject to all relevant safety requirements. The
Reclamation Concrete Design Manuals specifically address design and construction related to the
work outlined in this section.

25.2 General Requirements

All concrete and masonry work must comply with applicable standards and regulations from the
Occupational Safety and Health Administration (OSHA) 29 C.F.R. 1926 Subpart Q, Concrete and
Masonry Construction, and the American National Standards Institute (ANSI)/American Society of
Safety Professionals (ASSP) A10.9-2013 (R2018), Safety Requirements for Concrete and
Masonry Work.

25.3 Responsibilities
25.3.1 Area Office Safety Professional
25.3.1.1 Shall review and provide feedback on the work plan (see paragraph 25.5, Pre-Job
Briefing and Planning Requirements).

25.3.2 Professional Engineer (PE)

25.3.2.1 Shall design and certify all concrete conveyance systems, concrete pumping systems,
booms and boom supporting structures or equipment placement, boom mountings,
concrete pumps, formwork or vertical shoring installations, precast concrete temporary
shoring and bracing systems, and lift-slab operations as safe for intended use.

25.3.3 First-Line Supervisors

25.3.3.1 Shall review work plans.

(RSHS 032) 07/09/2021 25-1

NEW RELEASE
(Minor revisions approved 12/14/2022)
Reclamation Safety and Health Standards
January 2023 Section 25: Concrete, Masonry, and Formwork
25.3.3.2 Must create and seek approval of a Job Hazard Analysis (JHA) prior to performing this
work.

25.3.3.3 Shall review and sign JHAs and Risk Analysis or Exposure Assessment forms.

25.3.3.4 Shall supervise, or ensure supervision of, all employees by an individual(s) competent
in performing the assigned duties.

25.3.4 Employees
25.3.4.1 Shall report any change in conditions or hazards to the first-line supervisor or the job
lead.

25.3.4.2 Shall coordinate with the first-line supervisor to incorporate ergonomic considerations
into the work planning, particularly any work that includes prolonged exposure to
kneeling, bending, squatting, or other awkward body positions.

25.4 Hazard Identification, Assessment, and Safety Measures

25.4.1 Vertical Work
Employees must establish a limited access zone for vertical work, or masonry wall work,
prior to the start of construction. The zone must be equal to the height of the wall, plus 4
feet, running the entire length of the vertical work. Additionally, employees must establish
the zone on the un-scaffolded side, restrict access to only personnel actively engaged in or
supervising the work, and maintain the zone until the vertical work is self-supporting and
fully cured or is supported to prevent overturning and collapse. All vertical work over 8 feet
in height shall have bracing on both vertical sides until permanent supporting elements of
the structure are in place.

25.4.2 Green Cutting, Concrete Sawing, or Abrasive Blasting

Employees must address and mitigate any silica dust hazards that result from green cutting,
concrete sawing, or abrasive blasting (see OSHA 29 C.F.R. 1926.1153, Toxic and
Hazardous Substances – Respirable Crystalline Silica). RSHS Section 32, Respiratory
Protection, determines protocols for employee protections against silica dust hazards.

25.4.3 Exposed Rebar

Employees must mitigate exposed rebar hazards before work begins. Exposed rebar poses
catching, tripping, and impalement hazards.

(RSHS 032) 07/09/2021 25-2

NEW RELEASE
(Minor revisions approved 12/14/2022)
Reclamation Safety and Health Standards
January 2023 Section 25: Concrete, Masonry, and Formwork
25.5 Pre-job Briefing and Planning Requirements
25.5.1 Work Plan
The work plan will detail the phases of concrete and masonry operations. The first-line
supervisor must develop the sequencing of structural prior to the creation of the work plan.
The work plan must identify all possible safety hazards and plans for mitigation, including
those identified in the JHA. The work plan must include clear direction on the use of
Reclamation Manual Policy SAF P01 Appendix A, Stop Work Procedures. Additionally, the
work plan must also include a site map with identified staging and work zones, a limited
access zone for vertical work and shoring, and plans for erection and removal of formwork,
shoring, and vertical work.

25.5.2 Job Hazard Analysis

The first-line supervisor must create a JHA for specific tasks (e.g., formwork, pouring,
shoring, scaffolding) (see RSHS Section 4, Work Safety Planning for details).

25.5.3 Precast Concrete Plan

A PE must design all precast concrete operations plans. These plans shall include detailed
instructions, installation drawings, clear information on delivery and staging, equipment and
method for placement, support and shoring during installation, connections and couplings,
and lift planning. The work plan must include the precast concrete plan as described in
paragraph 25.5.1, Work Plan, of this section.

25.6 Hazardous Environmental Conditions (Weather/Other)

25.6.1 Rain and Stormwater Runoff
Drainage for precipitation at the excavation work site shall direct rainwater away from the
concrete formwork and fresh pours. Employees must use diversion ditches, dikes, or other
means to prevent rainwater or other precipitation from entering the work site. Employees
must use safe measures to prevent stormwater runoff from entering the work site.

25.6.2 Lightning
Work shall cease if lightning is spotted or reported within 5 miles of the work site. Work may
resume when lightning is no longer present within a 5-mile radius of the work site.

25.6.3 Wind
Employees must manage loose materials and spoil piles to not allow wind to blow the
materials into the active work area. Blowing particles or materials must not interfere with the

(RSHS 032) 07/09/2021 25-3

NEW RELEASE
(Minor revisions approved 12/14/2022)
Reclamation Safety and Health Standards
January 2023 Section 25: Concrete, Masonry, and Formwork
ability of the workers to safely complete their duties. First-line supervisors and employees
must monitor wind for its hazardous effects on the stability of structures, materials, and
workers. Blowing particles or materials shall not interfere with the ability of workers to safely
complete duties.

25.7 Personal Protective Equipment (PPE)

Employees placing or finishing concrete must wear applicable PPE, the minimum requirement
being long-sleeved shirts, long pants, rubber safety boots, gloves, hardhat, and eyeglasses with
side shields. The job site must provide eyewash facilities at each placement or finishing operation.
Employees engaged in green cutting must wear eye and face protection. Employees engaged in
wet or dry abrasive blasting using silica sand must wear an approved abrasive blasting air-line
respirator, heavy-duty footwear, leather or rubber gloves, face/eye protection, and hardhat.

25.8 Safe Practices

25.8.1 Plants and Equipment
Refer to RSHS Section 20, Mobile and Stationary Mechanized Equipment, for additional
mechanized construction equipment requirements.

25.8.1.1 Batching and Screening Plants. Job sites must provide concrete batching and
screening plants, aggregate production plants, hoppers, bins, silos, and related
equipment designed with a safety factor to prevent structural failure or collapse. Job
sites must provide batching plants, aggregate plants, and conveyor systems
equipped with mechanical dust control, water spray systems, and/or other
acceptable means to keep airborne dust concentrations within acceptable exposure
limits. Employees must comply with permit-required confined space and hazardous
energy control procedures (see RSHS Section 14, Confined Spaces and Permit-
Required Confined Spaces (2020)) when entering silos, storage bins, tunnels, shafts,
or similar enclosed areas.

25.8.1.2 Bulk Storage Bins. Bulk storage bins, containers, and silos must have conical or
tapered bottoms and be able to start material flow mechanically or pneumatically.

25.8.1.3 Loading Skips. Loading skips 1 cubic-yard or larger must have protective
guardrails installed on each side as well as a mechanical device to clear material.

(RSHS 032) 07/09/2021 25-4

NEW RELEASE
(Minor revisions approved 12/14/2022)
Reclamation Safety and Health Standards
January 2023 Section 25: Concrete, Masonry, and Formwork
25.8.1.4 Bull Floats. Where bull float handles may contact energized electrical conductors,
employees must establish a hazardous energy control clearance and lock out the
power to those conductors. Where bull float handles might contact energized
electrical sources, the first-line supervisor must ensure the handles are
nonconductive, or have an insulated sheath equivalent to nonconductive materials.

25.8.1.5 Powered Concrete Trowels. Manually-guided, powered, and rotating concrete

troweling machines must have a control switch or positive mechanical release device
which automatically stops trowel rotation when the operator releases the equipment
handle.

25.8.1.6 Concrete Buggies. Handles of concrete buggies must not extend beyond the
wheels on either side.

25.8.1.7 Concrete Buckets. Concrete buckets equipped with hydraulic or pneumatically

operated gates, must have positive safety latches, or similar safety devices, to
prevent premature or accidental dumping. Buckets must not accumulate aggregate
on the bucket’s top and sides. Personnel must not ride in concrete buckets or
walk/stand under buckets as they are raised or lowered into position by cranes or
cableways. Operators must not route elevated concrete buckets over employees.
Concrete buckets with manually operated gates must contain self-closing
mechanisms. First-line supervisors and employees must maintain all buckets in
structurally sound condition. A PE must approve any alterations which affect
structural competency.

25.8.1.8 Transmix Trucks. Transmix trucks and concrete pumping trucks, including
operating procedures, must conform with requirements set in RSHS Section 20,
Mobile and Stationary Mechanized Equipment.

25.8.2 Masonry Construction

Employees must establish a limited access zone when erecting a masonry wall as described
in paragraph 25.4.1, Vertical work, of this section. The supports must be able to withstand a
load of at least 15 pounds per square inch.

25.8.2.1 Equipment. Employees must only use masonry saws with semicircular guard-
enclosures over the blade and a slotted horizontal hinged bar mounted underneath
the guard enclosure to retain fragments of shattered blades. Employees must use

(RSHS 032) 07/09/2021 25-5

NEW RELEASE
(Minor revisions approved 12/14/2022)
Reclamation Safety and Health Standards
January 2023 Section 25: Concrete, Masonry, and Formwork
saws equipped with dust-control systems or provisions for wet sawing to control
airborne dust concentrations.

25.8.2.2 Scaffolding. Masonry scaffolding shall have a loading capacity, at a minimum, of

50 pounds per square foot (psf). Scaffolding shall comply with RSHS Section 13,
Walking and Working Surfaces. Facilities or job sites must provide guardrails, safety
nets, or personal fall protection systems for employees working 4 feet or more above
any ground or adjacent working surface.

25.8.3 Concrete Conveyance Systems

The manufacturer, or a PE, must design and certify all concrete conveyance systems and
supporting equipment as safe for intended use. Only competent personnel shall assemble,
operate, maintain, inspect, and test the systems in accordance with requirements set forth in
the manufacturer’s instructions, PE's specifications, or the standards found in this RSHS
section. Facilities or job sites must protect all operating platforms with guardrails and must
guard all dangerous moving parts.

25.8.4 Reinforcing Steel

25.8.4.1 Lateral Supports. Employees must laterally support reinforcing steel for walls,
piers, columns, and similar structures to prevent overturning or collapse. The lateral
supports for reinforcing steel must be able to withstand the forces applied during
construction.

25.8.4.2 Rigging. Employees must securely tie bundles of reinforcing steel together before
moving by crane or cableway to prevent slipping. Employees must use two-part
slings to handle steel more than 20 feet long. See RSHS Section 18, Slings, Rigging
Hardware, and Wire Rope.

25.8.4.3 Impalement. First-line supervisors or employees must eliminate the hazard of

impalement by covering exposed rebar. Plastic cap coverings are not sufficient
impalement protection. Employees must cover vertically protruding rebar with wood
troughs or other substantial material.

25.8.4.4 Positioning Device Systems. Employees must use a positioning device when
working in a stationary location 4 feet, or higher, above any adjacent work surfaces
or when placing and tying reinforcing steel in walls, piers, columns, etc. Employees

(RSHS 032) 07/09/2021 25-6

NEW RELEASE
(Minor revisions approved 12/14/2022)
Reclamation Safety and Health Standards
January 2023 Section 25: Concrete, Masonry, and Formwork
must use a personal fall arrest system when moving on reinforcing steel higher than
24 feet above adjacent surfaces.

25.8.4.5 Walkways. Reinforcing mats used as walkways must have planking to ensure safe
footing.

25.8.4.6 Prohibited Uses. Employees will not use reinforcing steel as guy attachments at
any anchorage points for scaffolding hooks, stirrups, or as a load-bearing member of
any lifting device.

25.8.4.7 Wire Mesh Mats. Employees must secure wire mesh reinforcing mats at the end
of each mat to prevent recoiling and secure unrolled wire mesh on each side before
cutting.

25.8.4.8 Post Tensioning Operations. First-line supervisors must not permit employees,
except those essential to post-tensioning operations, behind the jack during
tensioning operations. First-line supervisors or qualified personnel must erect signs
and barricades to limit employee access to the post-tensioning area.

25.8.5 Formwork and Falsework

In addition to the specific requirements set forth in this section, the design and erection of
formwork or falsework must be in accordance with the latest edition of the American
Concrete Institute 347 Guide to Formwork for Concrete, the American Concrete Institute 318
Building Code Requirements for Reinforced Concrete, and the current edition of ANSI A10.9
Safety Requirements for Masonry and Concrete Work.

25.8.5.1 Safety Factor. Employees or qualified personnel must design, erect, brace, and
maintain formwork, falsework, structural shoring, and bracing to safely support all
vertical and lateral loads. First-line supervisors must incorporate the minimum safety
factors as specified in ANSI A10.9 in the design and erection of all framework,
shoring, falsework, and formwork accessories.

25.8.5.2 Construction Loads. Employees must not impose any construction loads on the
partially completed structures unless such loading has been considered in the
design, has been determined to be safe and capable of supporting the load by a PE,
and is shown on the formwork design drawings or specifications.

(RSHS 032) 07/09/2021 25-7

NEW RELEASE
(Minor revisions approved 12/14/2022)
Reclamation Safety and Health Standards
January 2023 Section 25: Concrete, Masonry, and Formwork
25.8.5.3 Drawings and Plans. A PE must approve and sign detailed design calculations
and working drawings for all formwork or vertical shoring installations when any of
the following conditions exist:

• the height, as measured from the top of the sills to the soffit of the
superstructure, exceeds 14 feet,
• individual horizon span lengths exceed 16 feet, and/or
• provisions are made for vehicular or railroad traffic through the falsework
or vertical shoring.

For all formwork and vertical shoring installations not discussed above, one of the
following must approve and sign the formwork plan or shoring layout:

• PE,
• manufacturer’s authorized representative, or
• contractor’s representative qualified in using and erecting formwork and
vertical shoring.

A PE must make drawings or plans showing the jack layout, formwork, shoring,
working decks, and scaffolding available at the jobsite.

25.8.5.4 Form Anchors. A PE must design form anchors, which support forms and
scaffolding, with a minimum safety factor of three. Employees must not impose load
on form anchors or concrete anchorages until the concrete has set the minimum
period set forth in paragraph 25.8.8, Releasing and Moving Forms of this section.
Form sections supported by form anchors must be no more than 50 feet long and
employees must design and install the form anchors so no forces, incurred by form
or anchorage failure, can transfer to an adjacent section.

25.8.5.5 Housekeeping. In all areas where persons must work or pass, employees must
promptly remove and stockpile all stripped forms and shoring. Additionally,
employees must pull or cut protruding nails, wire ties, and other unneeded
accessories to avoid hazards.

25.8.5.6 Fall Protection. Employees, when working 6 feet or more above any adjacent
work surface (and not protected by fixed scaffolding, guardrails, or safety net), must
use a personal fall protection system. Employees working in a stationary position
may use a positioning system, but only until relocating.

25.8.6 Vertical Shoring

(RSHS 032) 07/09/2021 25-8

NEW RELEASE
(Minor revisions approved 12/14/2022)
Reclamation Safety and Health Standards
January 2023 Section 25: Concrete, Masonry, and Formwork
25.8.6.1 Additional Loading. Employees must only temporarily store reinforcing rods,
materials, or equipment on top of formwork if structures have been designed or
strengthened to support the additional loading. Employees must not load eccentric
loads on shore heads or similar members unless these members are designed for
intended loading.

25.8.6.2 Sills. Sills used in shoring must be sound, rigid, and able to carry the maximum
intended load.

25.8.6.3 Inspection. The first-line supervisor or project lead must conduct visual
inspections of vertical work and shoring during erection, prior to use, and during use.
The first-line supervisor must also ensure all equipment conforms to the shoring
layout and there is no damaged equipment. The first-line supervisor or qualified
personnel must immediately reinforce or reshore any damaged or weakened shoring
equipment. Work shall stop if the inspection indicates critical failure potential or
unmitigated hazards. Work shall resume when the first-line supervisor or project lead
has addressed the issue and the hazard is abated.

25.8.6.4 Reshoring. Employees must provide reshoring when necessary to safely support
slabs and beams after stripping or where such structures are subject to
superimposed loads.

25.8.6.5 Removal of Shoring. Employees must only remove shoring equipment after the
concrete has reached the minimum strength required in the formwork and shoring
design and a PE or supervisor has inspected and approved the placement. First-line
supervisors or PEs must plan removal so as not overload in-place shoring
equipment.

25.8.7 Vertical Slip Forms

A PE experienced in slip-form design must design any vertical slip forms. The first-line
supervisor must make a copy of the designs available on the jobsite. The first-line supervisor
must have experience with vertical slip forms and shall oversee all vertical slip form
operations. The first-line supervisor must be present on the deck during slipping.

25.8.7.1 Jack Supports. A PE must design any steel rods or pipes on which the jacks
climb (or by which forms are lifted) for that purpose. Employees must encase
supports in concrete or anchor the supports to the ground. Supports anchored or

(RSHS 032) 07/09/2021 25-9

NEW RELEASE
(Minor revisions approved 12/14/2022)
Reclamation Safety and Health Standards
January 2023 Section 25: Concrete, Masonry, and Formwork
secured by form anchors must use two or more independent form anchors,
separated by a minimum of 5 vertical feet.

25.8.7.2 Vertical Loading. Employees must position jacks and vertical supports to equally
distribute vertical loads. Loads must not exceed the capacity of the jacks.

25.8.7.3 Line and Plumb. Employees must keep the form structure in line and plumb
during jacking operations.

25.8.7.4 Lifting. Employees must not exceed the predetermined safe rate of lift.

25.8.7.5 Bracing. Employees must provide lateral and diagonal form bracing to prevent
excessive distortion of the structure during jacking.

25.8.7.6 Holding Devices. The job site must provide jacks or other lifting devices with
mechanical dogs and other automatic holding devices for protection in case the
power supply or lifting mechanism fails.

25.8.7.7 Scaffolding and Platforms. Vertical lift forms must have scaffolding or work
platforms which completely encircle the area of placement.

25.8.8 Releasing and Moving Forms

Any form raising or moving by crane, cableway, A-frame, or other mechanical lifting device,
requires a lift plan. Personnel shall not ride forms or scaffolding during lifts. Personnel shall
not be directly underneath any lifted forms.

25.8.8.1 Lifting. When raising or moving forms by crane, cableway, A-frame, or similar
mechanical lifting device, employees must securely attach the forms to wire rope
slings with a minimum safety factor of 8. Employees must equip the panels and form
sections with hoisting brackets to attach slings and must remove loose tools and
materials before moving forms. Employees must use taglines for controlling forms
whenever necessary to protect personnel or structures.

25.8.8.2 Releasing. Employees must adequately brace or secure vertical and overhead
forms before releasing them. Before releasing and moving forms, the first-line
supervisor must relocate any employees at risk to falling materials.

(RSHS 032) 07/09/2021 25-10

NEW RELEASE
(Minor revisions approved 12/14/2022)
Reclamation Safety and Health Standards
January 2023 Section 25: Concrete, Masonry, and Formwork
25.8.8.3 Form Removal. Employees must not remove forms, shoring, or bracing until the
first-line supervisor or the job lead have determined the concrete is sufficiently strong
to support its weight with all loads placed on it.

25.8.9 Precast Concrete

Employees must brace precast concrete walls, structural framing, or tilt-up wall panels until
after making permanent connections.

25.8.9.1 Temporary Bracing. A PE must design temporary bracing for precast concrete
walls, structural framing, or tilt-up wall panels. Such bracing must provide at least 15
psf on projected surfaces.

25.8.9.2 Suspended Loads. First-line supervisors must not allow employees under
precast concrete members as lifted or tilted into position.

25.8.9.3 Lifting Inserts. The lifting inserts for tilt-up concrete members must be able to
support at least two times the maximum intended load. Other types of lifting inserts
for precast concrete members must be able to support at least four times the
maximum intended load. Lifting hardware must be able to support at least five times
the maximum intended load.

25.8.10 Lift-Slab Operations

A PE experienced in lift-slab construction shall design and plan all lift-slab operations. Such
plans shall include detailed instructions and design drawings which prescribe the method of
erection and ensure lateral stability of the structure.

25.8.10.1 Jacks/Lifting Units. Employees must mark jacks/lifting units to show the rated
capacity established by the manufacturer. Employees must not load jacks/lifting units
beyond the rated capacity and must install a safety device for jacks/lifting units to
ensure loads will remain supported in any position if jacks malfunction.

25.8.10.2 Jacking Operations. Operators must synchronize jacking operations so the slab
will remain level at all support points to within a 0.5-inch tolerance. If leveling is
automatically controlled, job sites must install a device which will stop the operation
when tolerance is exceeded or when the jacking system malfunctions. If manual
controls maintain leveling, the operator must locate these controls in a central
location. An experienced, competent person must attend the controls during lifting.
First-line supervisors must limit the maximum number of manually controlled

(RSHS 032) 07/09/2021 25-11

NEW RELEASE
(Minor revisions approved 12/14/2022)
Reclamation Safety and Health Standards
January 2023 Section 25: Concrete, Masonry, and Formwork
jacks/lifting units on one slab so the operator can maintain the slab level. The
maximum number must not exceed fourteen jacks/lifting units. During jacking
operations, only essential employees may remain in the building/structure.

25.8.10.2.1 Wedges. When making temporary connections to support slabs,

employees must secure wedges with tack welding, or an equivalent
method, to prevent them from falling out of position. Employees will
only release lifting rods after securing column wedges.
25.8.10.2.2 Welding. A certified welder must perform all welding on temporary
and permanent connections. Employees must not execute load
transfer from jack/lifting units to building columns until the welds on
the column shear plates cool to air temperature.
25.8.10.2.3 Secure Installation. Employees must secure jacks/lifting units to
building columns so to not dislodge or dislocate. The PE must design,
and employees must install, equipment so the lifting rods cannot slip
out of position.

25.9 Definitions in Appendix K and References in Appendix L

(RSHS 032) 07/09/2021 25-12

NEW RELEASE
(Minor revisions approved 12/14/2022)