Findings Report: Formwork 2022
A findings report on a formwork inspection blitz led by SafeWork NSW in April - June 2022.
Project timeframe: April - June 2022
Recent incidents
Workplace incidents on worksites across NSW have led to devastating consequences and serious injuries when:
- workers have fallen from one level to another
- workers have been hit by falling objects
- structures have collapsed
- inferior and / or mix matched componentry is used.
The formwork industry has informed SafeWork NSW there is a worldwide supply issue of LVL bearers and general timber shortages, which has seen collapses and accidents to workers in NSW. Formwork companies are urged to conduct audits on their timber supplies to ensure all components, including imported materials, meet Australian Standards.
Summary and overview
To address these concerns, SafeWork inspectors visited 90 sites to reduce the number of formwork incidents in NSW with Principal Contractors collaborating with subcontractors to ensure safe formwork systems and practices are implemented.
Sites visited:
- mid-high rise - 31%
- commercial - 22%
- infrastructure - 20%
- house construction - 18%
- other (townhouse construction, low-rise residential construction, mid-rise residential class 2, nursing home facility, storey towers) - 9%.
Type of formwork:
- conventional - 75%
- modular - 6%
- multiple types (conventional and modular, conventional and peri, conventional and ischebeck modular, prop and panel, conventional, DOKA, conventional, shutter) - 12%
- prop and panel - 4%
- slip/jump - 4%
The major risks related to formwork include:
- falls from platform edges or through penetrations
- being hit by falling timbers or crane loads formwork collapse
- contact with powerlines.
What stage formwork was in when inspected:
- under construction - 53%
- completed and ready for pouring (signed off by competent person) - 13%
- being poured - 11%
- poured and awaiting dismantling - 10%
- being dismantled - 7%
- other (part of slab has been poured; starter bars are in place for low wall) - 6%
Notices and fines
Due to the high level of compliance on sites, only a small number of notices were issued. Issues identified included falls from a solid structure, an unsafe workplace, scaffolding incomplete and electrical risks.
111 notices with $14,400 fines issued.
Observations
Planning for safety
What’s working well:
- 99% of all formworkers were inducted to the site by the principal contractor
- 96% implemented exclusion zones during construction/pouring/dismantling of the formwork
- 82% had a formwork plan or design in place that is signed off by a competent person
- 80% of principle contractors were aware there is a Code of Practice for Formwork.
Formwork observations (structure or build)
What’s working well:
- 95% had safeguards against overhead electric powerlines where required?
- 85% had suitable safe access and egress to and from the formwork decks.
- 84% had adequate control measures in place to prevent the risk of falling objects.
- 86 % had all working decks with adequate controls in place to prevent a person from falling through penetrations.
- 71% had all working decks with adequate protections in place to prevent a person falling from the edge of the deck.
Form working
What’s working well:
- 100% of the formwork observed by Inspectors was dismantled and lowered in a controlled manner
- 86% had the formwork design/plans readily available to form workers.
Conclusion
This formwork intervention program observed a high level of compliance in several safety categories. These are encouraging results. However, there was a small number of areas where the compliance was slightly lower, particularly when looking at safety protection to prevent a person from falling off the edge of decks and through penetrations.
Other areas of comparatively lower compliance were around having a competent person to sign off on the formwork plans and designs, along with having these readily available for form workers.
Considering the recent events and incidents identified by inspectors, Safework NSW will develop an intervention program to address these issues along with the lower compliance areas identified in this report.
SafeWork NSW recommendation
SafeWork will continue to work with major industry stakeholders through its state-wide dedicated construction teams to increase awareness, education, and improve overall safety standards and commitment to formwork risks in the NSW construction industry.