Precast Concrete Safety Manual

Precast Concrete Manufacturing Hazards

Precast plants combine the hazards of concrete work with those of heavy manufacturing.

Potential hazards include:

• Cement and concrete exposure
• Respirable crystalline silica
• Batch plants and mixers
• Conveyors and material-handling systems
• Machine hazards
• Reinforcing steel
• Forms and molds
• Prestressing equipment
• Stored energy
• Overhead cranes
• Rigging
• Suspended loads
• Heavy precast components
• Crushing and caught-between hazards
• Forklifts and mobile equipment
• Cutting, grinding, and finishing
• Noise
• Chemical products
• Electrical equipment
• Maintenance activities

Employees should receive training appropriate to the work they perform and the hazards they may encounter.

Precast Production Planning

Safe precast production begins before concrete is placed.

Planning should consider:

• Product dimensions and weight
• Form and mold requirements
• Reinforcing requirements
• Embedded components
• Prestressing requirements when applicable
• Concrete placement methods
• Lifting points and inserts
• Crane and rigging requirements
• Form-stripping procedures
• Product movement
• Storage configuration
• Loading and shipment

Employees involved in production should understand the procedures applicable to their assigned work.

Batch Plant Safety

Batch plants may contain conveyors, aggregate bins, cement silos, mixers, augers, gates, elevators, pneumatic systems, electrical equipment, and other machinery.

Employees should:

• Remain clear of moving machinery.
• Maintain guards.
• Follow established operating procedures.
• Avoid entering hazardous equipment areas without appropriate controls.
• Report damaged equipment.
• Maintain good housekeeping.
• Follow lockout/tagout procedures when required.

Employees should not reach into operating equipment to clear material or correct a malfunction.

Concrete Mixing Equipment

Mixers can expose employees to powerful rotating components and hazardous stored energy.

Employees should:

• Keep guards and covers in place.
• Avoid reaching into mixers.
• Use designated access points.
• Follow shutdown procedures.
• Control hazardous energy before servicing or entering equipment.
• Report abnormal equipment operation.

Entry into mixers for cleaning, inspection, or maintenance should be carefully controlled and evaluated for applicable lockout/tagout and confined-space requirements.

Aggregate & Cement Handling

Employees may be exposed to dust and moving equipment while handling cement, sand, aggregate, supplementary cementitious materials, and other ingredients.

Controls should address:

• Dust generation
• Material transfer
• Conveyor hazards
• Silos and bins
• Mobile equipment
• Housekeeping
• PPE
• Respiratory exposure
• Material spills

Dry cement and other powdered materials should be handled in a manner that minimizes unnecessary airborne dust.

Cement & Wet Concrete Exposure

Wet concrete and cement-containing products can cause skin irritation and serious chemical burns.

Employees should avoid prolonged or repeated skin contact.

Protective measures may include:

• Suitable gloves
• Protective clothing
• Waterproof footwear
• Eye and face protection
• Washing facilities
• Prompt removal of contaminated clothing

Employees should understand that cement burns may develop even when initial discomfort appears minor.

Silica Exposure

Precast operations can generate respirable crystalline silica when concrete or silica-containing materials are:

• Cut
• Sawed
• Drilled
• Ground
• Chipped
• Sanded
• Crushed
• Abraded
• Cleaned using methods that generate dust

The facility should evaluate silica-generating activities and implement appropriate exposure controls.

Controls may include:

• Wet methods
• Local exhaust ventilation
• Dust collection
• Isolation
• Work-practice controls
• Appropriate housekeeping
• Respiratory protection when required

Employees performing silica-generating work should receive appropriate training.

Forms & Molds

Precast products may be manufactured using steel, wood, fiberglass, or other mold and form systems.

Employees should:

• Inspect forms before use.
• Verify components are properly assembled.
• Maintain structural stability.
• Keep hands clear of pinch points.
• Use appropriate tools.
• Follow established opening and closing procedures.
• Control movable form components.
• Report damaged forms.

Forms should be capable of safely supporting the loads imposed during production.

Form Assembly

Form assembly may involve heavy panels, hardware, clamps, bolts, hydraulic systems, and powered tools.

Employees should:

• Maintain stable positioning of components.
• Use mechanical assistance when appropriate.
• Keep body parts clear of pinch points.
• Use suitable access equipment.
• Wear required PPE.
• Follow lifting and rigging procedures for heavy components.

Employees should not work beneath unsecured form components.

Form Release Agents

Release agents and other chemicals used on molds and forms should be handled according to manufacturer information and facility procedures.

Employees should:

• Review labels and Safety Data Sheets.
• Use appropriate PPE.
• Avoid unnecessary skin and eye contact.
• Maintain ventilation when necessary.
• Control overspray.
• Store products appropriately.

Reinforcing Steel

Precast products may contain reinforcing bars, welded wire reinforcement, cages, inserts, plates, and other embedded components.

Employees should be protected from hazards such as:

• Sharp edges
• Cuts
• Pinch points
• Impalement
• Falling material
• Unstable reinforcing assemblies
• Manual handling
• Crane and rigging operations

Reinforcing assemblies should be adequately supported before and during concrete placement.

Reinforcing Cage Fabrication

Employees fabricating reinforcement may perform cutting, bending, tying, welding, and assembly.

Procedures should address:

• Machine guarding
• Cutting equipment
• Rebar bending equipment
• Welding
• Hand tools
• Material handling
• Sharp edges
• PPE

Large reinforcing cages should be handled and stored to prevent collapse or unexpected movement.

Prestressed Concrete Operations

Facilities manufacturing prestressed products may tension steel strands or tendons to very high forces.

Prestressing operations can create severe struck-by hazards if strands, anchors, equipment, or components fail.

Procedures should establish controlled areas around prestressing operations.

Employees should:

• Remain outside hazardous line-of-fire areas.
• Follow established stressing sequences.
• Use equipment designed for the operation.
• Inspect applicable equipment.
• Follow manufacturer and engineering requirements.
• Maintain appropriate communication.
• Keep unnecessary personnel away.

Only trained and authorized employees should perform prestressing operations.

Prestressing Line-of-Fire Hazards

Employees should never unnecessarily position themselves directly in line with tensioned strands, stressing equipment, anchors, or other components capable of releasing stored energy.

Restricted areas should be established where necessary to protect employees from potential recoil or component failure.

Stored Energy

Precast manufacturing may involve stored energy in:

• Prestressing systems
• Hydraulic systems
• Pneumatic systems
• Springs
• Elevated equipment
• Pressurized lines
• Machinery
• Electrical systems

Stored energy should be identified and controlled before servicing, maintenance, or other work that could expose employees to unexpected release.

Concrete Placement

Concrete placement into molds may involve buckets, conveyors, pumps, hoppers, or other systems.

Employees should remain clear of:

• Moving equipment
• Suspended buckets
• Pinch points
• Discharge gates
• Pressurized lines
• Mobile equipment

Communication should be maintained between equipment operators and employees involved in placement.

Concrete Buckets

Concrete buckets may be moved by overhead crane or other lifting equipment.

Employees should:

• Remain clear of suspended buckets.
• Avoid positioning themselves beneath loads.
• Keep hands away from discharge gates.
• Maintain communication with the operator.
• Control swinging where practical.
• Use tag lines when appropriate.

Employees should not ride concrete buckets.

Concrete Vibrators

Internal and external vibrators may expose employees to electrical, ergonomic, noise, and equipment hazards.

Employees should:

• Inspect equipment.
• Maintain cords and connections.
• Use appropriate PPE.
• Avoid unsafe contact with moving components.
• Follow manufacturer instructions.

Finishing Operations

Precast products may require screeding, troweling, patching, grinding, sanding, cutting, drilling, or other finishing work.

Potential hazards include:

• Silica dust
• Flying particles
• Rotating equipment
• Noise
• Electrical hazards
• Repetitive motion
• Manual handling

Appropriate guards, dust controls, PPE, and work practices should be used.

Concrete Cutting & Grinding

Cutting and grinding cured concrete can generate significant respirable crystalline silica and expose employees to blades, wheels, flying debris, and noise.

Employees should:

• Use appropriate dust controls.
• Maintain machine guards.
• Inspect blades and wheels.
• Wear required eye and face protection.
• Use hearing protection when necessary.
• Maintain stable positioning.
• Follow equipment instructions.

Curing Operations

Precast concrete may be cured using ambient conditions, heat, steam, heated enclosures, or other controlled processes.

Potential hazards may include:

• Heat
• Steam
• Hot surfaces
• Pressurized systems
• Restricted spaces
• Electrical equipment

Employees should follow established curing-system procedures and avoid unauthorized entry into hazardous areas.

Form Stripping

Removing forms from cured products can expose employees to shifting components, pinch points, falling material, suspended loads, and unexpected movement.

Before stripping forms:

• Verify applicable production requirements have been met.
• Establish safe employee positions.
• Control movable components.
• Use appropriate lifting equipment.
• Maintain communication.
• Keep employees clear of potential fall or movement zones.

Employees should not position themselves beneath unsecured form sections.

Lifting Inserts & Attachment Points

Precast components may incorporate engineered lifting inserts, anchors, loops, or other attachment points.

Lifting devices should be:

• Appropriate for the insert or attachment system.
• Used according to applicable design information.
• Inspected before use.
• Properly engaged before lifting.

Employees should not substitute improvised attachment methods for designed lifting systems.

Overhead Crane Safety

Overhead and gantry cranes are commonly used to move forms, reinforcing assemblies, molds, and finished precast components.

Crane procedures should address:

• Operator authorization
• Pre-use inspections
• Rated capacity
• Load control
• Travel paths
• Communication
• Suspended-load hazards
• Employee positioning

Employees should remain clear of suspended loads and areas where shifting loads could crush or strike them.

Rigging

Slings, chains, wire rope, shackles, hooks, spreader beams, lifting clutches, and other rigging should be appropriate for the load and lifting configuration.

Employees involved in rigging should:

• Know or determine load weight.
• Select suitable rigging.
• Inspect equipment before use.
• Protect rigging from damaging edges when necessary.
• Maintain appropriate sling angles.
• Control loads during movement.
• Keep personnel clear.

Defective rigging should be removed from service.

Suspended Loads

Precast products can weigh several tons or more.

Employees should never unnecessarily position themselves:

• Beneath suspended precast components
• Between a suspended load and fixed structure
• Between precast components
• Inside a potential swing path
• Where shifting or falling material could trap them

Load-control procedures should minimize employee exposure to crushing and struck-by hazards.

Pinch & Crush Hazards

Employees may be exposed to pinch and crush points during:

• Form assembly
• Form stripping
• Product lifting
• Product positioning
• Stacking
• Loading
• Mold changes
• Equipment operation

Employees should maintain safe body positioning and avoid placing hands, feet, or other body parts between heavy components.

Product Handling

Finished precast components should be moved according to procedures appropriate for their size, shape, weight, and lifting configuration.

Before movement:

• Determine the load weight.
• Verify lifting points.
• Select appropriate equipment.
• Establish the travel path.
• Remove unnecessary personnel.
• Identify potential pinch and crush zones.
• Establish communication.

Precast Product Storage

Finished components should be stored on stable surfaces using appropriate supports.

Storage procedures should consider:

• Product geometry
• Weight
• Center of gravity
• Ground conditions
• Dunnage
• Blocking
• Stacking configuration
• Wind exposure
• Access
• Future lifting requirements

Products should be secured or supported to prevent unintended movement, overturning, or collapse.

Dunnage & Blocking

Dunnage and blocking should be appropriately sized, positioned, and maintained for the loads they support.

Employees should:

• Inspect supports.
• Keep hands clear during placement.
• Use tools where practical.
• Avoid standing between unstable components.
• Verify components are stable before releasing lifting equipment.

Yard Safety

Precast yards may contain cranes, forklifts, loaders, trucks, trailers, stored products, uneven surfaces, and employees on foot.

Yard procedures should address:

• Traffic routes
• Pedestrian areas
• Speed
• Backing
• Blind spots
• Equipment operating zones
• Lighting
• Product storage
• Communication

Pedestrians should maintain awareness of moving equipment.

Forklift Safety

Forklifts may be used for materials, supplies, smaller precast components, and production equipment.

Only trained and authorized employees should operate powered industrial trucks.

Operators should:

• Inspect equipment.
• Observe rated capacities.
• Maintain load stability.
• Control speed.
• Watch for pedestrians.
• Maintain visibility.
• Follow facility traffic rules.

Heavy & Mobile Equipment

Precast facilities may use loaders, skid steers, yard tractors, forklifts, mobile cranes, trucks, and other equipment.

Procedures should address:

• Operator authorization
• Equipment inspections
• Seat belts
• Backing
• Blind spots
• Pedestrian exposure
• Equipment stability
• Spotters when appropriate
• Traffic control

Backing Safety

Drivers and equipment operators should minimize unnecessary backing where practical.

Before backing:

• Check the travel path.
• Account for pedestrians.
• Use mirrors and cameras.
• Sound appropriate warnings.
• Back at a controlled speed.
• Use a spotter when conditions warrant.

Spotters should remain visible to the operator and stay outside the equipment’s travel path.

Loading Precast Products

Loading finished precast components onto trucks or trailers can expose employees to suspended loads, unstable products, rigging hazards, mobile equipment, and falls.

Loading should be planned based on:

• Product dimensions
• Weight
• Trailer capacity
• Load distribution
• Lifting configuration
• Product orientation
• Dunnage
• Securement requirements
• Unloading sequence

Employees should remain clear of suspended products and crushing zones.

Load Securement

Precast products should be appropriately positioned and secured for transportation.

Employees performing securement should:

• Use suitable securement equipment.
• Inspect chains, binders, straps, and other devices.
• Maintain stable footing.
• Avoid line-of-fire positions.
• Use appropriate access methods.
• Verify product stability.

Employees should not climb on loads when safer access methods are available.

Shipping & Receiving

Truck traffic should be controlled during loading, unloading, and delivery activities.

Procedures should address:

• Driver communication
• Parking locations
• Loading areas
• Pedestrian separation
• Trailer positioning
• Vehicle movement
• Product securement
• Release of vehicles

Machine Guarding

Production machinery should be appropriately guarded to protect employees from moving parts and points of operation.

Equipment may include:

• Mixers
• Conveyors
• Rebar-processing equipment
• Saws
• Grinders
• Pumps
• Material-handling systems
• Other production machinery

Employees should not bypass or remove required guards.

Lockout/Tagout

Employees performing servicing or maintenance may be exposed to electrical, mechanical, hydraulic, pneumatic, gravitational, thermal, or other hazardous energy.

Applicable lockout/tagout procedures should be followed when unexpected startup or release of stored energy could cause injury.

Equipment requiring energy control may include:

• Mixers
• Conveyors
• Batch equipment
• Hydraulic forms
• Pumps
• Saws
• Prestressing equipment
• Material-handling systems
• Other machinery

Only trained and authorized employees should perform lockout/tagout.

Electrical Safety

Employees should:

• Report damaged electrical equipment.
• Keep electrical panels accessible.
• Avoid unauthorized electrical repairs.
• Protect cords from damage.
• Use equipment appropriate for wet or damp conditions.
• Follow electrical safe-work practices.

Only qualified personnel should perform electrical work requiring specialized qualifications.

Hand & Power Tool Safety

Precast production and maintenance may involve grinders, saws, drills, impact tools, pneumatic tools, and other equipment.

Tools should:

• Be appropriate for the task.
• Be inspected before use.
• Have required guards.
• Be maintained in safe condition.
• Be removed from service when defective.

Employees should use appropriate PPE.

Welding & Hot Work

Welding and cutting may be used for reinforcing assemblies, embedded steel, forms, equipment maintenance, and repairs.

Hot-work procedures should address:

• Fire prevention
• Combustible materials
• Ventilation
• Welding screens
• PPE
• Compressed gases
• Fire watch when required
• Hot-work authorization when applicable

Hazard Communication

Precast plants may use:

• Cement
• Admixtures
• Form-release agents
• Curing compounds
• Epoxies
• Sealers
• Fuels
• Oils
• Welding products
• Cleaning chemicals
• Repair products

Hazardous chemicals should be addressed through the facility’s Hazard Communication Program as applicable.

Employees should have access to labels and Safety Data Sheets and receive appropriate training.

Personal Protective Equipment

PPE should be selected according to the hazards of the task.

Depending on operations, PPE may include:

• Hard hats
• Safety glasses
• Goggles
• Face shields
• Work gloves
• Chemical-resistant gloves
• Protective footwear
• High-visibility clothing
• Hearing protection
• Respiratory protection
• Fall-protection equipment

Hearing Conservation

Batch plants, vibrators, saws, grinders, compressors, heavy equipment, and other machinery can create hazardous noise.

Employee exposure should be evaluated and appropriate controls implemented.

Where required, hearing-conservation measures should address:

• Exposure monitoring
• Engineering and administrative controls
• Hearing protection
• Audiometric testing
• Training

Fall Protection

Employees may be exposed to falls from:

• Elevated products
• Forms
• Platforms
• Mezzanines
• Trucks and trailers
• Production equipment
• Storage areas

Fall hazards should be evaluated and appropriate controls established.

Employees should use designated access systems rather than climbing precast products or machinery.

Ladders & Access

Ladders, stairs, platforms, and other access equipment should be appropriate for the work and maintained in safe condition.

Employees should not use pallets, forms, products, or other makeshift means of access.

Walking-Working Surfaces

Production floors and yards should be maintained to reduce:

• Slips
• Trips
• Falls
• Uneven surfaces
• Obstructions
• Standing water
• Concrete residue

Employees should use designated walkways where provided.

Housekeeping

Good housekeeping is especially important around batch plants and production areas.

Employees should:

• Remove spilled materials.
• Maintain clear aisles.
• Control concrete residue.
• Store tools properly.
• Keep electrical panels accessible.
• Maintain access to emergency equipment.
• Keep walking surfaces clear.

Dry sweeping or compressed-air cleaning methods that unnecessarily create airborne silica-containing dust should be avoided where prohibited or inappropriate.

Ergonomics & Manual Material Handling

Employees may repeatedly handle reinforcing steel, inserts, hardware, tools, hoses, finishing equipment, and other materials.

Mechanical assistance should be used when practical for heavy or awkward loads.

Employees should:

• Evaluate loads before lifting.
• Avoid unnecessary twisting.
• Use team lifting when appropriate.
• Use carts and lifting devices.
• Arrange materials to reduce excessive reaching.

Heat Stress

Employees may work around curing systems, hot production environments, or outdoor yards during warm weather.

Heat-illness prevention measures may include:

• Water
• Rest
• Shade or cooling
• Ventilation
• Acclimatization
• Employee monitoring
• Training

Cold Stress

Outdoor production and yard operations may expose employees to cold, wind, rain, snow, or ice.

Employees should use appropriate clothing and warming opportunities and recognize signs of cold-related illness.

Emergency Procedures

Precast facilities should establish procedures for foreseeable emergencies such as:

• Serious employee injury
• Crushing or struck-by incidents
• Suspended-load emergencies
• Prestressing failures
• Equipment entanglement
• Cement or chemical exposure
• Fire
• Electrical emergencies
• Severe weather
• Medical emergencies

Employees should know how to stop applicable equipment and summon emergency assistance.

Incident Reporting & Investigation

Employees should promptly report:

• Injuries
• Near misses
• Crane and rigging incidents
• Dropped loads
• Prestressing incidents
• Equipment malfunctions
• Guarding deficiencies
• Chemical exposures
• Silica-control problems
• Vehicle incidents
• Product instability

Investigations should evaluate contributing factors such as:

• Equipment condition
• Rigging
• Product stability
• Employee positioning
• Procedures
• Training
• Communication
• Machine guarding
• Energy control
• Maintenance

Corrective actions should address identified causes where practical.

Precast Concrete Manufacturing Safety Training

Training should correspond to assigned duties and workplace hazards.

Training may include:

• Batch plant safety
• Concrete mixing
• Cement exposure
• Silica
• Forms and molds
• Reinforcing steel
• Prestressing
• Line-of-fire hazards
• Concrete placement
• Form stripping
• Crane safety
• Rigging
• Suspended loads
• Precast product handling
• Yard safety
• Forklift and mobile equipment
• Loading and securement
• Machine guarding
• Lockout/Tagout
• Electrical safety
• Hand and power tools
• Welding and hot work
• Hazard Communication
• PPE
• Hearing conservation
• Fall protection
• Emergency procedures
• Incident reporting

Additional training should be provided when new equipment, products, processes, chemicals, or hazards are introduced.

Customized Precast Concrete Manufacturing Safety Manuals

Precast concrete manufacturers vary significantly in products, production methods, plant equipment, mold systems, reinforcing operations, lifting equipment, yard configurations, and employee exposures. Facilities may manufacture architectural panels, structural members, utility products, pipe, barriers, vaults, drainage products, transportation components, or other precast concrete products.

A customized Precast Concrete Manufacturing Safety Manual can be developed around your batch plant, production equipment, molds, reinforcing and prestressing operations, silica-generating activities, cranes and rigging, finished-product handling, storage yard, loading operations, maintenance activities, and employee exposures.