Product Overview

This Shotcrete Grouting and Concrete Repair Safe Work Method Statement (SWMS) provides a structured, step-by-step approach to identify hazards, assess risks, and implement controls for all phases of sprayed concrete and repair works. It is a comprehensive document that consolidates multiple shotcrete, grouting and concrete repair activities to support robust WHS compliance on Australian construction sites.

Activities & Specific Tasks Covered

This document includes specific risk controls for:

• Application of shotcrete to walls, slabs, columns and overhead surfaces, including setup, spraying and finishing
• Shotcreting operations using wet-mix and dry-mix systems, including management of rebound, overspray and dust
• Sprayed concrete placement in confined, restricted or difficult-to-access areas with appropriate ventilation and exclusion zones
• Chipping concrete surfaces using jackhammers, breakers and hand tools to remove loose, delaminated or defective concrete
• Surface preparation for repair works, including cleaning, profiling and ensuring adequate key for bonding of new materials
• Expansive grouting for crack injection, void filling and structural strengthening, including pressure control and curing considerations
• Injection grouting procedures for leaks, voids and structural defects using cementitious, epoxy or polyurethane products
• Repairing cracks and joints in concrete, including routing, sealing, joint reinstatement and compatibility with existing structures
• Handling, mixing and application of cementitious, epoxy and chemical grouts, including controls for skin and respiratory exposure
• Management of dust, silica exposure and airborne contaminants generated during chipping, cutting and surface preparation
• Manual handling and ergonomic controls for hoses, nozzles, bags of material, pumps and ancillary equipment
• Safe setup, operation and shutdown of shotcrete pumps, compressors and mixing equipment, including lockout/tagout procedures
• Working at height or on scaffolds, platforms and elevated work areas while applying or repairing concrete surfaces
• Control of noise, vibration and flying debris to protect workers, other trades and the public in adjacent work areas
• Environmental management of washout water, excess grout and concrete waste to prevent site and stormwater contamination

Who is this for?

This SWMS is designed for shotcrete contractors, concrete repair specialists, grouting technicians, civil and structural contractors, and site supervisors overseeing sprayed concrete and concrete remediation works.

Specific Job Steps & Hazards Covered

Legislation & References

This document was researched and developed to align with:

• Code of Practice: Construction Work – Guidance on managing risks associated with construction activities including concrete and shotcrete operations
• Code of Practice: Managing the Risk of Falls at Workplaces – Requirements for working at height during shotcrete and repair works
• Code of Practice: Managing Noise and Preventing Hearing Loss at Work – Controls for noise from pumps, compressors, breakers and other plant
• Code of Practice: Managing Risks of Hazardous Chemicals in the Workplace – Safe use, storage and handling of grouts, admixtures, epoxies and chemical products
• Code of Practice: Managing the Risk of Respirable Crystalline Silica from Engineered Stone in the Workplace – Applied principles for controlling silica dust from concrete chipping and surface preparation
• Code of Practice: Confined Spaces – Where shotcrete or grouting is undertaken in pits, tanks or other confined spaces
• AS 1379: Specification and supply of concrete – Guidance on concrete properties and handling relevant to shotcrete and repair materials
• AS 2550 series: Cranes, hoists and winches – Safe use – Where lifting equipment is used to position pumps, hoses or materials
• AS/NZS 1715 & AS/NZS 1716: Respiratory protective devices – Selection, use and maintenance of RPE for dust and fume control
• AS/NZS 1801: Occupational protective helmets – Requirements for head protection on construction sites
• AS/NZS 2161 series: Occupational protective gloves – Hand protection against cementitious and chemical products
• AS/NZS 2210 series: Occupational protective footwear – Protective footwear suitable for wet, uneven and debris-laden surfaces
• Work Health and Safety Act 2011
• Work Health and Safety Regulations 2017