Concrete cutting contractors perform specialized sawing, drilling, coring, grinding, removal, and modification of concrete, masonry, asphalt, and similar materials. Work may be performed during new construction, renovation, demolition, utility installation, structural modification, roadway work, industrial maintenance, and facility upgrades.
Concrete cutting and drilling operations can expose employees to high-speed cutting equipment, rotating blades and bits, respirable crystalline silica, flying debris, noise, water and electricity, hydraulic and pneumatic systems, falling materials, structural hazards, traffic, confined work areas, and heavy concrete sections.
A Concrete Cutting Contractor Safety Manual establishes procedures for controlling these hazards while operating concrete saws, core drills, wall saws, wire saws, grinders, demolition equipment, and related tools.
The safety manual should reflect the company’s actual equipment, cutting and drilling methods, work environments, materials, customer requirements, and employee exposures.
Concrete cutting contractors may encounter hazards involving:
Employees should receive training appropriate to the equipment and work they perform.
Concrete cutting and drilling work should be planned before equipment is set up.
Planning should consider:
Work should not begin until significant hazards have been evaluated and appropriate controls established.
Conditions should be evaluated for each project because concrete cutting operations can vary considerably.
The assessment should address hazards associated with:
Required controls and PPE should be identified before work begins.
The area to be cut or drilled should be inspected before work begins.
Employees should determine whether the work could affect:
Both sides of a wall, floor, ceiling, or other surface should be considered where practical.
Concrete can conceal electrical conduit, plumbing, gas lines, communication systems, process piping, and other utilities.
Before penetrating concrete, available information should be reviewed to determine whether utilities may be present.
Where appropriate, locating methods may include:
Employees should not assume that concrete is clear simply because no utilities are visible.
Cutting or drilling into post-tensioned concrete can create serious hazards.
Before work involving potentially post-tensioned construction begins, the contractor should determine whether tendons may be present and obtain appropriate information regarding their location.
Employees should not cut or drill through post-tensioning components unless the work has been specifically evaluated and authorized.
Concrete cutting can alter the strength or stability of structural components.
Before cutting structural or potentially load-bearing components, the work should be evaluated by the appropriate responsible party.
Employees should not make unauthorized cuts in:
Required shoring, bracing, sequencing, or engineering controls should be established before cutting begins.
Concrete cutting areas should be controlled to protect employees and others from:
Controls may include:
Unauthorized persons should be kept away from active cutting operations.
Only trained and authorized employees should operate concrete saws.
Operators should:
Equipment should not be operated with required safety devices removed or defeated.
Walk-behind saws may be used for cutting:
Operators should maintain control of the machine and follow manufacturer instructions for blade installation, cutting depth, travel direction, and operation.
The work area should be maintained to prevent other employees from entering the saw’s operating path.
Handheld concrete saws can create substantial kickback, silica, noise, and flying-particle hazards.
Operators should:
Employees should not use handheld saws from unstable positions.
Wall saw systems may involve tracks, hydraulic or electric power units, large blades, and remote controls.
Before operation:
Employees should remain outside the blade and potential falling-material hazard areas.
Diamond wire saw systems can create severe hazards because of wire speed, stored energy, and the large cutting areas involved.
Work areas should be established to keep employees away from:
Only employees necessary for the operation should remain within controlled areas.
Core drilling may be performed through floors, walls, ceilings, slabs, foundations, and structural components.
Before drilling, employees should evaluate:
Drilling equipment should be securely positioned.
Drill stands should be installed according to manufacturer instructions.
The mounting method should be appropriate for the surface and equipment.
Employees should verify stability before drilling begins.
Makeshift or inadequately secured mounting arrangements should not be used.
Concrete cores can be extremely heavy and may fall unexpectedly when drilling is completed.
The area below or behind the core should be controlled before penetration is completed.
Employees should consider:
Large cores may require mechanical lifting or other controlled removal methods.
Horizontal drilling may cause the core to release from the opposite side of a wall.
Employees should barricade or otherwise control the opposite side where exposure exists.
The core should be removed using a method that prevents uncontrolled movement.
Overhead drilling can expose employees to:
Equipment should be securely mounted, and the work area should be controlled.
Appropriate methods should be used to capture or control the core.
Blades and bits should be:
Damaged, cracked, excessively worn, or incompatible blades and bits should not be used.
Required blade guards should remain installed and properly adjusted.
Employees should not modify or remove guards simply to obtain additional cutting access.
Alternative equipment or methods should be used when the required cut cannot be safely completed with the guard in place.
Saw blades can bind, pinch, or kick back when:
Operators should understand equipment-specific kickback zones and avoid positioning themselves in the potential path of the saw.
Large or complex cuts should be planned to prevent uncontrolled:
Cutting sequence should account for the support and removal of each section.
Cut sections may weigh hundreds or thousands of pounds.
Before completing a cut, employees should determine how the material will be:
Employees should never stand beneath or within the potential movement path of inadequately supported concrete.
Large concrete sections may require cranes, hoists, forklifts, excavators, or other lifting equipment.
Rigging should be selected according to the anticipated load.
Employees should:
Only qualified or trained personnel should perform applicable rigging activities.
Cutting floors, walls, roofs, or elevated surfaces can create fall and falling-object hazards.
New openings should be protected as work progresses.
Protection may include:
Floor-hole covers should be capable of performing their intended protective function and should be secured where required.
Concrete cutting may occur near:
Applicable fall-protection requirements should be followed.
Employees should receive training appropriate to the fall-protection systems they use.
Cutting, sawing, drilling, grinding, and chipping concrete and masonry can generate respirable crystalline silica.
Flanagan Consulting Corporation requires silica-generating activities to be evaluated and controlled according to applicable requirements.
Controls may include:
Employees should follow the Company’s Silica Exposure Control Program.
Where required, Flanagan Consulting Corporation will establish and implement a written exposure control plan addressing silica-generating activities.
The plan should identify applicable:
A competent person should perform the responsibilities required by the applicable silica standard.
Water-delivery systems are commonly used to reduce airborne silica during concrete cutting.
Water should be supplied at a rate sufficient for the intended dust-control method.
Employees should:
Wet cutting does not eliminate other saw hazards.
Where dust collection is used, equipment should be compatible with the tool and maintained according to manufacturer instructions.
Employees should inspect:
Dust should be removed and disposed of in a manner that minimizes employee exposure.
HEPA-filtered vacuum systems should be used where required by the applicable exposure-control method.
Vacuum equipment should be maintained and emptied in a manner that minimizes release of collected dust.
Dry cutting can produce substantial airborne dust.
Dry cutting should not be used simply for convenience when required dust-control measures cannot be maintained.
Where dry methods are permitted, applicable engineering controls, work practices, exposure assessments, and respiratory protection should be implemented.
Employees should not use dry sweeping or dry brushing for silica-containing dust where prohibited and feasible alternatives are available.
Appropriate cleaning methods may include:
Compressed air should not be used to disperse silica-containing dust except where permitted under applicable requirements.
Where respirators are required, Flanagan Consulting Corporation will maintain an appropriate Respiratory Protection Program.
Required elements may include:
Employees should not substitute voluntary respirator use for required engineering controls.
Wet cutting creates a significant interaction between electrical equipment and water.
Employees should:
Employees should not handle energized electrical components while standing in uncontrolled water.
Electrical equipment used for construction work should have applicable ground-fault protection.
Ground-fault circuit interrupters should be tested and used as required.
Damaged electrical equipment should be removed from service.
Extension cords should:
Cords should not be repaired or modified using unauthorized methods.
Wet concrete cutting produces slurry containing fine concrete particles.
Slurry should be controlled to prevent:
Employees should use appropriate collection, containment, or disposal methods.
Concrete cutting work can create slippery surfaces from:
Work areas should be maintained as orderly as practical.
Slurry and standing water should be controlled promptly.
Concrete saws and drills may use hydraulic power.
Employees should inspect:
Hydraulic leaks should not be checked with bare hands.
Pressure should be relieved before applicable servicing.
Pneumatic tools and equipment should be operated within manufacturer specifications.
Employees should:
Gasoline, diesel, or other fuel-powered equipment can create:
Equipment should be fueled and operated according to manufacturer instructions.
Fuel-powered saws and equipment can generate dangerous carbon monoxide concentrations, particularly indoors or in enclosed or poorly ventilated areas.
Fuel-powered equipment should not be operated indoors or in enclosed areas unless the work has been evaluated and appropriate controls established.
Controls may include:
Employees should understand that carbon monoxide cannot be reliably detected by smell.
Indoor concrete cutting can generate:
Adequate ventilation should be provided based on the hazards and work being performed.
Concrete cutting or drilling may occur in:
Employees should not enter confined spaces until the space has been evaluated and applicable entry procedures established.
Where permit-required confined-space requirements apply, the Company’s Confined Space Program should be followed.
Concrete saws, drills, grinders, chipping tools, compressors, and demolition equipment can generate hazardous noise.
Flanagan Consulting Corporation will evaluate employee noise exposure where required.
Controls may include:
Employees covered by applicable requirements should participate in the Company’s Hearing Conservation Program.
Frequent use of handheld saws, drills, grinders, and chipping equipment can expose employees to vibration.
Employees should:
PPE should be selected according to the hazards of the task.
PPE may include:
Concrete cutting can generate high-speed particles and slurry.
Appropriate eye protection should be worn.
Face shields may be necessary during operations with significant flying-particle or splash hazards but should be used with appropriate primary eye protection where required.
Gloves should be selected for hazards involving:
Employees should avoid placing hands near moving blades or bits regardless of glove use.
Safety footwear should be appropriate for:
Additional protection may be necessary where substantial crushing hazards exist.
Concrete cutting contractors may use:
Tools should be inspected before use and maintained in safe condition.
Defective tools should be removed from service.
Grinding concrete can generate silica, sparks, debris, and noise.
Employees should use:
Grinding wheels should be compatible with the tool and rated for its operating speed.
Chipping hammers, breakers, and similar equipment can create:
Employees should establish controlled work areas and use appropriate exposure controls.
Required guards should be maintained on saws, grinders, and other equipment.
Employees should not:
Employees performing servicing or maintenance where unexpected startup or release of hazardous energy could cause injury should follow applicable energy-control procedures.
Energy sources may include:
Only authorized employees should perform covered lockout/tagout activities.
Cutting and drilling equipment should be inspected before use.
Inspections may include:
Defective equipment should be removed from service until repaired.
Preventive maintenance should be performed according to manufacturer recommendations and company procedures.
Only qualified or authorized employees should perform maintenance requiring specialized knowledge.
Equipment should be appropriately isolated before servicing.
Concrete cores, cut sections, equipment, blades, hoses, and other materials may be heavy or awkward.
Employees should use:
where practical.
Employees should avoid uncontrolled lifting of loads that exceed their safe capabilities.
Concrete cutting can involve:
Work should be planned to reduce unnecessary physical strain.
Mechanical positioning equipment should be used where practical.
Large concrete sections may require crane or hoisting operations.
Employees involved in lifting should understand:
Employees should not work beneath suspended loads.
Only trained and authorized employees should operate powered industrial trucks.
Operators should:
Concrete cutting may require work from aerial lifts.
Only trained and authorized employees should operate applicable equipment.
Employees should follow manufacturer instructions and applicable fall-protection requirements.
Where scaffolds are used, they should be erected, inspected, and used according to applicable requirements.
Employees should not overload scaffold platforms with heavy equipment or concrete sections.
Ladders should generally be used for access and light work rather than as platforms for heavy concrete cutting equipment.
Employees should:
Concrete cutting contractors may work on:
Traffic-control measures should be established where employees are exposed to vehicles or mobile equipment.
Appropriate traffic controls may include:
Employees should remain within established work areas whenever practical.
Employees may work around:
Employees should remain outside equipment blind spots and operating zones unless their work requires entry and appropriate communication has been established.
Employees operating company vehicles should:
Concrete saws, compressors, water tanks, generators, and other equipment may be transported on trailers.
Employees should inspect:
Loads should be properly distributed and secured.
Heavy equipment should be loaded and unloaded on suitable surfaces.
Employees should:
Concrete cutting may be performed in:
Additional controls may be needed for:
Work should be coordinated with the customer or controlling employer.
Work areas should be controlled to prevent members of the public from entering cutting, drilling, slurry, or equipment hazard zones.
Barricades and temporary barriers should be maintained where necessary.
Tools and equipment should be secured when unattended.
Concrete cutting frequently occurs alongside:
Work should be coordinated to prevent one employer’s activities from exposing another employer’s employees to uncontrolled hazards.
Concrete debris, cores, slurry, hoses, cords, blades, and equipment can create significant hazards.
Employees should:
Concrete debris and slurry should be disposed of according to applicable project and environmental requirements.
Employees should not discharge slurry into storm drains or other locations unless permitted.
Fire hazards may arise from:
Combustible materials should be controlled and appropriate fire extinguishers maintained where required.
Employees should receive Hazard Communication training appropriate to workplace chemicals.
Products may include:
Labels and Safety Data Sheets should be maintained as required.
Concrete cutting frequently involves strenuous work in hot environments.
Employees should have appropriate access to:
Employees should be trained to recognize symptoms of heat illness.
Cold weather can increase hazards associated with:
Appropriate clothing and warming practices should be used.
Employees should understand applicable emergency procedures for:
Employees working at customer sites should become familiar with applicable site emergency procedures.
Appropriate first-aid supplies should be accessible.
Employees should promptly report and obtain appropriate care for:
Certain concrete cutting tasks should not be performed alone when equipment, lifting requirements, confined spaces, structural hazards, or emergency-response considerations require additional personnel.
Where employees perform appropriate work alone, communication and emergency procedures should be established.
Employees should promptly report:
Significant incidents and near misses should be investigated to identify contributing causes.
Investigations may consider:
Corrective actions should address identified causes where practical.
Employee training should correspond to assigned duties and may include:
Training should be updated when employees are assigned new equipment, tasks, cutting methods, or workplace hazards.
Concrete cutting contractors vary considerably in the services they provide. Some primarily perform slab sawing and core drilling, while others specialize in wall sawing, wire sawing, roadway cutting, structural modifications, demolition cutting, industrial work, or large-scale concrete removal.
A customized Concrete Cutting Contractor Safety Manual can be developed around your concrete sawing and drilling services, equipment, silica exposures, wet-cutting methods, structural work, rigging, material removal, vehicles, customer sites, construction projects, and employee hazards.