Risk Assessments · Mandatory · Pre-Construction

RAMS — Concrete Pours

This RAMS covers the safe delivery, placement, and curing of concrete including pump operations, formwork loading, vibration, and manual handling of tools. It addresses skin contact risks from wet cement, vehicle movements during delivery, formwork adequacy checks, and temporary works stability during and after the pour.

Last reviewed: 29 March 2026 — This guide reflects UK law as of this date. MHSWR 1999 remains current with no amendments enacted as of 29 March 2026. Next scheduled review: 29 March 2027.

Legal basis	MHSWR 1999 Regulation 3 + CDM 2015 Part 4 + COSHH 2002 (cement / silica) + LOLER 1998 (pump boom) + HAV Regulations 2005 (vibrators)
Key guidance	BS 5975:2019 (Code of practice for temporary works procedures); COSHH Essentials for construction; EH40 WELs for silica and cement
Who	Concreting contractor, formwork contractor, pump operator
COSHH substances	Wet cement (alkaline pH 12-13, causes burns); hexavalent chromium Cr(VI) (sensitiser in cement); respirable crystalline silica (RCS) during cutting/chasing
Temporary works	All formwork and falsework must be designed, checked, and inspected under BS 5975:2019 procedures with TWC/TWS in place
Enforcing authority	Health and Safety Executive (HSE)

1. What It Covers

Concrete pours are among the most hazardous routine operations on a construction site. A RAMS for this work scope must address every phase of the concreting process — from formwork design and erection through to striking and curing. The hazards combine structural risk (formwork collapse), chemical risk (cement burns, chromium sensitisation, silica dust), plant risk (pump boom and hose), and physical risk (vibration, manual handling, falls from formwork).

The legal framework draws on multiple regulations. CDM 2015 Part 4 applies to the structural aspects of formwork and falsework. COSHH 2002 applies to wet cement, hexavalent chromium, and respirable crystalline silica. LOLER 1998 applies to the concrete pump boom as a lifting appliance. The Control of Vibration at Work Regulations 2005 apply to poker vibrators. BS 5975:2019 provides the mandatory code of practice for all temporary works procedures including formwork and falsework design, checking, and inspection.

Formwork collapse is the single greatest structural risk during concrete pours

Wet concrete exerts hydrostatic pressure on formwork that increases with pour rate and height. Formwork that is under-designed, incorrectly erected, or not inspected before the pour can fail suddenly and without warning. Formwork collapses during pours have resulted in multiple fatalities. The BS 5975:2019 temporary works procedure — including independent design check and pre-pour inspection — is the primary control against this risk.

2. Pour Phases

A concrete pour is not a single activity but a sequence of five distinct phases, each with its own hazard profile and competence requirements. The RAMS must address every phase individually and set out the controls, responsibilities, and hold points for each.

Phase	Activities	Key hazards	Hold points	Responsible person
1. Design and planning	Formwork design, falsework design, temporary works design brief, pour sequence planning, concrete mix specification	Design error leading to formwork failure; inadequate pour rate limits; insufficient reinforcement cover	TWD design check complete and signed off by TWC before materials ordered	Temporary Works Designer (TWD) / Temporary Works Coordinator (TWC)
2. Formwork erection	Erection of formwork panels, propping, bracing, installation of ties, fixing of reinforcement, placement of cast-in items	Falls from formwork; manual handling of panels and props; struck by falling components; inadequate propping	Formwork inspection by TWC (or delegate) before reinforcement fixing begins	Formwork erector / TWC
3. Pre-pour inspection	Formal inspection of completed formwork, reinforcement, and falsework against the design drawings; permit to pour issued	Failure to identify defects before concrete is placed; missing ties or props; incorrect reinforcement position	Permit to pour signed by TWC confirming formwork and reinforcement comply with design	TWC / site engineer
4. Concrete placement	Concrete delivery, pump setup, placing, vibrating (compacting), levelling, finishing; monitoring formwork during pour	Cement burns; pump hose whip; pump boom collapse; HAV from vibrators; formwork overload; manual handling	Pour rate monitored against design limit; formwork monitored for deflection throughout pour	Concrete gang supervisor / pump operator
5. Curing and striking	Curing regime (covering, temperature control); striking formwork and falsework in planned sequence; back-propping where required	Premature striking before concrete achieves required strength; falls during striking; manual handling of formwork	Cube test results confirm concrete has achieved required strength before striking authorised by TWC	TWC / site engineer

“No concrete shall be placed until the temporary works coordinator has confirmed that the formwork and falsework have been erected in accordance with the design and are fit to receive the load.”— BS 5975:2019, Clause 6

3. Key Hazards

The following table sets out the principal hazards associated with concrete pours, who is at risk, the key risk factors, and the control measures that should be addressed in the RAMS.

Hazard	Who at risk	Risk factors	Control measures
Formwork collapse	Concrete gang, formwork erectors, adjacent trades	Under-designed formwork; incorrect erection; missing ties or props; pour rate exceeding design limit; impact from concrete delivery	BS 5975:2019 temporary works procedure; TWD design; independent check; TWC pre-pour inspection; permit to pour; pour rate monitoring; formwork deflection monitoring during pour
Cement burns (alkaline burns)	Concrete gang, labourers, finishers	Wet cement contact with skin (pH 12-13); kneeling in wet concrete; splashes to eyes; prolonged contact through wet clothing	Waterproof gloves; long-sleeved clothing; waterproof trousers; eye protection; immediate wash facilities; toolbox talk on cement burn recognition; first aid procedure for cement burns
Hexavalent chromium (Cr VI) dermatitis	All operatives handling wet cement	Cr(VI) is a skin sensitiser present in Portland cement; repeated exposure causes allergic contact dermatitis which is irreversible once sensitised	COSHH assessment; use of low-chromate cement where available; waterproof barrier gloves (not fabric); skin care regime; health surveillance for dermatitis; occupational health referral if symptoms develop
Respirable crystalline silica (RCS)	Operatives cutting, chasing, or grinding cured concrete	Cutting concrete with disc cutters, angle grinders, or scabblers generates airborne RCS; WEL 0.1 mg/m3 8-hour TWA	Water suppression on all cutting tools; on-tool extraction where practicable; RPE (minimum FFP3) where dust cannot be controlled at source; COSHH assessment; health surveillance (lung function testing)
Pump hose whip	Concrete gang at the delivery end of the pump line	Blocked pump line releasing under pressure; defective coupling; hose movement during placement; air in the line	Hose restraints at all couplings; competent pump operator; pre-pour pump inspection; communication protocol between pump operator and placing gang; emergency stop procedure
Pump boom collapse	All operatives in the vicinity of the concrete pump	Outrigger failure; ground bearing failure; boom overload; boom striking overhead obstacles or structures	LOLER-compliant inspection of pump (thorough examination in date); outrigger setup on firm ground; ground bearing assessment; boom radius within rated capacity; exclusion zone around pump base
Hand-arm vibration (HAV) from poker vibrators	Concrete vibrator operatives	Prolonged use of poker vibrators during compaction; vibration magnitude typically 5-15 m/s2; exposure action value 2.5 m/s2 daily	HAV assessment; exposure time limits calculated from vibration magnitude; task rotation between operatives; low-vibration equipment where available; gloves for warmth (not anti-vibration gloves, which are ineffective for this frequency range); health surveillance
Falls from formwork	Formwork erectors, concrete gang, finishers	Working at edge of formwork during erection, reinforcement fixing, concrete placement, and finishing; access to elevated pours	Edge protection to formwork perimeter; safe access (scaffold staircase, ladder access platform); harness and lanyard where edge protection not practicable; safety netting below where appropriate
Manual handling	Formwork erectors, concrete gang, labourers	Formwork panels, props, reinforcement bars, pump hoses, vibrators; repetitive handling in awkward postures	Mechanical handling (crane, telehandler) wherever practicable; two-person lifts for heavy panels and props; manual handling assessment; task rotation

4. Competence Requirements

Concrete pours require specific competence for each role involved in the formwork, placement, and finishing process. The RAMS must confirm that all operatives hold the required qualifications and that evidence has been verified before work begins.

Role	Required competence
Concreter / concrete finisher	NVQ Level 2 in Concrete Placing and Finishing (or Trowel Occupations with concrete specialism); CSCS Skilled Worker (blue) card; site-specific induction; COSHH awareness for cement and silica
Formwork erector	NVQ Level 2 in Formwork; CSCS Skilled Worker (blue) card; working at height training; manual handling training; understanding of BS 5975:2019 requirements
Temporary Works Coordinator (TWC)	CITB or equivalent TWC training course; appointed in writing by the principal contractor; responsible for managing all temporary works on site including formwork/falsework design check, inspection, and permit to load/pour
Temporary Works Supervisor (TWS)	TWS training course; responsible for supervising erection of temporary works on site and confirming compliance with design drawings; reports to the TWC
Concrete pump operator	CPCS Concrete Pump Operator card (or manufacturer training certification); thorough examination of pump in date under LOLER; competent in outrigger setup and boom operation; pre-use inspection trained
Vibrator operative	Trained in use of poker vibrator; HAV awareness training; understanding of compaction requirements and over-vibration risks; exposure time limits briefed

The TWC/TWS roles are distinct and must be formally appointed

BS 5975:2019 requires that the Temporary Works Coordinator (TWC) and Temporary Works Supervisor (TWS) are formally appointed in writing. The TWC is responsible for the overall management of the temporary works process, including ensuring that designs are checked, inspections are carried out, and permits to load are issued. The TWS is responsible for supervising the physical erection of temporary works on site and confirming that the as-built condition matches the design. These roles must not be combined with the role of the operative carrying out the work.

5. Common Mistakes

No permit to pour issued before concrete placement begins

The permit to pour is the formal confirmation by the TWC that the formwork and reinforcement have been inspected and comply with the design. Placing concrete without a permit to pour bypasses the primary control against formwork collapse. The permit must be signed, dated, and retained on site. It is not a formality — it is the hold point that prevents loading of formwork that has not been verified as fit for purpose.

COSHH assessment missing for wet cement and silica exposure

Wet cement is a corrosive substance (pH 12-13) that causes alkaline burns on prolonged skin contact. Hexavalent chromium (Cr VI) in Portland cement is a skin sensitiser that causes allergic contact dermatitis. Respirable crystalline silica (RCS) is generated when cured concrete is cut or chased. All three require a COSHH assessment specifying the substance, the exposure route, the control measures, and the health surveillance requirements. A generic COSHH assessment that does not address each substance individually is not sufficient.

Pour rate exceeding the formwork design limit

Formwork is designed to withstand a specific maximum pour rate (typically expressed in metres per hour of vertical rise). Exceeding this rate increases the hydrostatic pressure on the formwork beyond its design capacity and can cause sudden failure. The pour rate must be monitored throughout the pour and the concrete gang must be briefed on the maximum rate before the pour begins. The pump operator must be in communication with the placing gang to control delivery rate.

Striking formwork before concrete achieves required strength

Formwork and falsework must not be struck until the concrete has achieved the required strength for the next construction stage. This is confirmed by cube test results, not by elapsed time alone. Premature striking can result in structural failure of the partially cured element. The TWC must authorise striking based on verified cube test results, and back-propping must be in place where specified by the designer.

No HAV assessment for poker vibrator operatives

Poker vibrators typically produce vibration magnitudes of 5-15 m/s2. The exposure action value under the Control of Vibration at Work Regulations 2005 is 2.5 m/s2 daily exposure. This means that operatives using poker vibrators can exceed the action value within minutes of continuous use. A HAV assessment must calculate the permitted exposure time for each operative based on the vibration magnitude of the specific equipment being used. Task rotation, exposure time limits, and health surveillance must all be in place.

6. Frequently Asked Questions

Does BS 5975:2019 apply to all formwork on site, including small pours?▾

Yes. BS 5975:2019 applies to all temporary works, including formwork and falsework for any concrete pour regardless of size. The level of formality in the temporary works procedure should be proportionate to the complexity and risk of the formwork, but the core requirements — design, check, inspect, permit to load — apply to every pour. A small kicker pour still requires a design appropriate to the load and a check that it has been erected correctly.

What health surveillance is required for operatives exposed to wet cement?▾

Operatives with regular skin contact with wet cement should be enrolled in a health surveillance programme for occupational dermatitis. This typically involves a baseline skin assessment at the start of employment, followed by periodic reviews (usually six-monthly or annually). Operatives should also be trained to recognise the early signs of dermatitis and instructed to report symptoms immediately. For silica exposure, lung function testing (spirometry) is required where exposure exceeds the action level.

Is the concrete pump boom classified as lifting equipment under LOLER?▾

Yes. A concrete pump boom is classified as lifting equipment under LOLER 1998 because it supports a load (the concrete within the boom and hose) at height. The pump must have a current thorough examination certificate (typically annual for the boom and six-monthly for any lifting accessories). The pump operator must carry out a pre-use inspection before each shift and any defects must be reported and rectified before use.

Can formwork be struck based on elapsed time rather than cube test results?▾

In practice, many sites use a combination of elapsed time and temperature monitoring to estimate concrete strength, particularly for routine pours in controlled conditions. However, BS 5975:2019 requires that striking is authorised by the TWC based on evidence that the concrete has achieved the required strength. Cube test results provide the most reliable evidence. Where maturity monitoring or time-temperature methods are used as an alternative, they must be calibrated against cube test data and the methodology must be agreed with the structural engineer.

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