Form Safety

By Gustavo A. Gonzalez

Forms, or molds, are one of the most common pieces of equipment in a precast plant. They come in various shapes and sizes. They may be as small as 18 inches by 18 inches or as big as 15 feet by 30 feet or even bigger. They are flat, round, rectangular and octagonal. But one thing they all have in common is the potential hazard for injury to the employee.

Not every form is built the same, and therefore the hazards presented by each will vary according to its construction and characteristics.

Forms consist of two main parts: the core and the outside walls. The core can be hinged and opened or collapsed by either mechanical, hydraulic or pneumatic components. Others are tapered so that the cured concrete piece can be removed by either extracting the core or pulling the piece out with the help of compressed air, hydraulic cylinders or mechanical means.

The outside walls (or jackets) also differ in design. Some open on four sides supported by springs or hydraulic cylinders, while others open on two L-shaped pieces sliding on a track. Still others are designed so that all four walls come apart with no support mechanism. Regardless of the type of walls, they are all held closed with bolts and nuts, clamps or some other mechanical device.

Quite a few hazards are inherent to these pieces of equipment. Hazards are posed by the energy behind hydraulic, pneumatic or mechanical components as well as heavy metal pieces that can crush or hit employees.

Fall hazards
According to Occupational Safety and Health Administration regulations and Canadian standards, employees must not be exposed to falls higher than 4 feet. This means that any employee working on a form 4 feet or more from the floor must have a platform with railings (or some other form of fall protection) to protect against falling. This also means that any employee working on top of the form must wear some kind of fall protection or restraining system to prevent falling off the edge.

Here are some safety recommendations to observe when working on any form where a fall hazard exists.

• All forms with walkways over 4 feet high must have guardrails
• All ladders, platforms and railings are in good condition
• All catwalks and platforms are clean and free of concrete deposits and objects such as chairs, silicone tubes, inserts and tools
• All chains and/or gates are in place and in good working order
• Hands are free when climbing
• Do not jump from the ladders to the floor
• Close all chains and gates when working in catwalks or platforms; open them only for getting on and off
• Do not place any buckets, ladders or other objects on any platform to extend your reach
• Keep all ladders free of oil, grease and concrete deposits
• Use the three-point system while ascending or descending: two hands and one foot touching the ladder at all times
• Do not climb on the form’s structural members
• Never climb on top of the guardrails
• Do not climb on top of forms unless you are using fall protection
• Do not climb on rolling wall forms when they are open unless they have a mechanism to keep the door in place
• Do not ride the concrete bucket to climb on a form
• Use the appropriate footwear; oil-resistant or anti-skid soles are the best

The use of portable or rolling ladders is recommended to reach the top of short forms as well as to place and vibrate concrete. Ladders must be inspected before use and any problems brought to the attention of the supervisor.

Do not use a defective ladder. Here are some basic rules for ladder usage:

• Must be completely open
• Do not step on the top two steps
• Only one person on the ladder
• Use the three-point system while ascending or descending: two hands and one foot touching the ladder at all times
• Keep ladder rungs clean and free of grease
• Remove buildup of material such as dirt or mud
• Face the ladder when climbing up or down
• Do not lean backward or sideways from the ladder
• Mark “Do not use” or throw away defective ladders

Form oil hazards
Most form oils are based on petroleum derivatives or contain animal fat which, when mixed with water, tend to create a very slippery surface and a potential slip and fall hazard. Shoes with oil resistant or anti-skid soles help decrease this hazard.

Wear eye or face protection when spraying forms to protect yourself. Avoid breathing the fumes – there should be plenty of ventilation, or if necessary use a respirator. Wash your hands before eating or smoking.

Air pressure sprayers should not be pressurized past their safe operating pressures and they should be equipped with some kind of pressure relief valve as a safety device. Check all sprayers daily to ensure they are in proper working order, hoses and handles are not leaking, and the equipment is ready to use.

Place close attention when transferring liquids or filling the sprayer. Do not overfill the container, and wipe all spills off the floor. If you are spraying outdoors, note the wind direction so that the spray does not blow back onto you. Also advise other personnel to stay away from the spraying operation.

Some release agents may irritate the eyes and skin, so check the Material Safety Data Sheet before using the product. Do not climb on top of a form to oil it; use a ladder. Always pick up the hose after spraying, and store the equipment out of the way. Hand-held sprayers should be stored in the upright position so the contents do not spill and create a slipping hazard.

Mechanical hazards
The inside of the core of some forms can be classified as a confined space. Any employee performing work inside a core must make sure that all sources of energy are isolated and locked as required. Do not go inside the core if you are not authorized to do so.

In hydraulically operated forms, the hoses and hydraulic components must be checked periodically for wear and tear. A broken hydraulic hose contains a lot of force and can spray hot hydraulic oil everywhere.

On spring-loaded doors, check the spring tension periodically. Also check the springs and their brackets and retainers to make sure they are in good working order. Do not allow them to drop by their own weight. Some are heavy, and this abuse will eventually damage the springs, creating a very hazardous condition. If necessary, use the hoist to let the doors down slowly.

On rolling doors check the wheels and tracks to ensure they stay in place when they are open. Make sure they are clean of debris and concrete so they roll easily when pushed. This is also a good way to eliminate back strain and sprain hazards. Do not overexert yourself when opening form doors. If necessary, seek help or use the hoist to assist you. Do not use a forklift to close the form’s doors, as this is dangerous and tends to get the doors out of square over time.

If it is not possible to lay individual wall panels on the floor, brace, crib or suspend them with a crane so they cannot fall on top of anyone.

Forms should be arranged in such a way that their doors can be fully opened and stairs easily accessed. This will eliminate tripping hazards, slips and falls.

Door latches, if so equipped, must be adjusted so they open and close with little effort. If the latch is not adjusted properly, the closing bar can and will spring back and could hit you in the head. The extra force required to close the latch can also create lower back problems.

Door bolts should be installed and removed using the correct wrench or socket. Be careful when using adjustable wrenches, as they tend to slip if not adjusted properly. Keep all tools free of grease and oil at all times.

Here are some other considerations:

• Watch your hands when opening and closing hinged cores
• Watch your hands and arms when opening and closing the outer walls
• If you must climb inside the form, use a ladder
• Do not connect the hooks from a sling to the pallet (shiplap) to raise it or lower it; use C-clamps in the four corners instead – it is safer.
• Do not set pallets (shiplaps) inside the form on PVC tubing or any soft material; use metal legs or 4 x 4 lumber
• Do not walk on top of a pallet or shiplap resting inside the form to reach around it
• Install as many components as possible while the rebar cage is on the floor

Panel safety
Panels are mostly used to build custom boxes. They are fabricated of high-density materials or aluminum attached to a frame. Most of the hazards are encountered when assembling or disassembling the panels. Consider the weight of the panels, and seek help lifting them when needed. Watch your fingers when attaching panels. Wear safety glasses when installing or removing pins, watch your fingers and make sure that pins are inserted properly.

Do not climb on the panels unless you are using fall protection. When taking panels apart, it is advisable to leave on a few ties.

Be careful when removing panels from the concrete when using a pry bar or a crowbar – it may slip and hit you. Never use a shovel to pry loose a panel or a piece of concrete from a form. When it is time to break the ties left in the concrete make sure you wear eye protection.

Conclusion
Working with forms can be a safe operation if we remember to identify the hazards and act accordingly. Wear the required Personal Protective Equipment and inspect your tools, ladders, railings and walkways daily. Follow the safety rules as required and bring to your supervisor’s attention any hazardous conditions or problems you may encounter. Remember, safety in the plant starts with you.

Gustavo Gonzalez has nearly 20 years of experience in the precast concrete industry. He has a bachelor’s degree in Industrial Engineering Technology from Florida International University and is a former precast concrete plant manager. He currently serves as an instructor for the National Safety Council and the National Precast Concrete Association.