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# POCKET

GUIDE
Workers Safety Series 

# Concrete Manufacturing

OSHA 3221 • 12N 2004

Manufacturing concrete can po se health and safety risks for the worker. For concrete manufacturing, the 10 OSHA standards most freque ntly included in the agency's citations were: 1. Hazard communication 2. Lockout/tagout 3. Confined spaces 4. Respiratory protection 5. Guarding floor & wall openings and holes 6. Electrical wiring methods 7. Noise exposure

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# Concrete Manufacturing

◾ More than 250,000 people work in concrete manufacturing.
◾ Over 10 percent of those workers - 28,000 - experienced a job-related injury or illness and 42 died in just one year.
◾ Potential hazards for workers in concrete manufacturing:

◦ Eye, skin and respiratory tract irritation from ex posure to cement dust;

◦ Inadequate safety guards on equipment;

◦ Inadequate lockout/tagout systems on machinery;

◦ Overexertion and awkward postures;

◦ Slips, trips and falls; and

◦ Chemical burns from wet concrete. 

# Hazards & Solutions Occupational Safety & Health Administration We Can Help What's New | Offices

Home Workers Regulations Enforcement Data & Statistics Training Publications Newsroom Small Business Anti-Retaliation Was this page helpful? 

# Page 1 of 10 Worker Safety Series - Concrete Manufacturin g

8 /4 /201 5 https://www.osha.gov/Publicati ons/concrete_manufacturing.htm l8. Forklifts 9. Electrical systems design 10. Machine guarding

Hazard: Exposure to cement dust can ir ritate eyes, nose, throat and th e upper respiratory system. Skin contact may result in moderate irritation to thicke ning/cracking of skin to severe skin damage from chemical burns. Silica exposure can lead to lu ng injuries including silicosis and lung cancer. Solutions:

◾ Rinse eyes with water if they come into cont act with cement dust and consult a physician.
◾ Use soap and water to wash off dust to avoid skin damage.
◾ Wear a P-, N- or R-95 respirator to minimize inhalation of cement dust.
◾ Eat and drink only in dust-free area s to avoid ingesting cement dust.

Hazard: Exposure to wet concrete can result in skin ir ritation or even first- , second- or third-degree chemical burns. Compounds such as hexavalent chromium may also be harmful. Solutions:

◾ Wear alkali-resistant gloves, covera lls with long sleeves and full-leng th pants, waterproof boots and

eye protection.
◾ Wash contaminated skin areas with cold, running water as soon as possible.
◾ Rinse eyes splashed with wet concrete with water fo r at least 15 minutes and th en go to the hospital

for further treatment. 

# Cement Dust

Wet Concrete

Machine Guarding Hazard: Unguarded machinery used in the manufacturing process can lead to worker injuries. Solutions:

◾ Maintain conveyor belt syst ems to avoid jamming and use care in clearing jams.
◾ Ensure that guards are in plac e to protect workers using mixers, block makers, cu bers and metalworking machinery such as rebar benders, cutters and

cage rollers.
◾ Establish and follow effective lockout/tago ut procedures when servicing equipment.
◾ Be sure appropriate guards are in pl ace on power tools before using them. 

# Page 2 of 10 Worker Safety Series - Concrete Manufacturin g

8 /4 /201 5 https://www.osha.gov/Publicati ons/concrete_manufacturing.htm lHazard: Improper lifting, awkward postures and repetitive motions can lead to sprains, strains and other musculoskeletal disorders. Solutions:

◾ Use handtrucks or fork lifts when possible.
◾ Lift properly and get a coworker tohelp if a product is too heavy.
◾ Avoid twisting while carrying a load. Shift your feet and take small st eps in the direction you want to

turn.
◾ Keep floors clear to avoid slipping and tripping hazards.
◾ Avoid working in awkward postures.

Hazard: Mixers and ready-mix trucks have confined spaces that pose safety risks for workers. Solutions:

◾ Follow established procedures for confined space entry and work to assure safety.
◾ Guard against heat stress when cleaning truck mixer drums.
◾ Wear appropriate protective equipment to avoid si lica exposure when removing concrete residues

from inside truck mixer drums.

Hazard: Poorly maintained or impr operly handled vehicles can lead to crushing injuries at the plant site or other injuries for truck drivers. Solutions:

◾ Make sure back-up alarms on all vehicles are functioning.
◾ Avoid overloading cranes and hoists.
◾ Use care with the load out chut e on concrete mixers to avoid injuries to hands and fingers.
◾ Beware of hot surfaces on equipment and truck components.
◾ Guard eyes against splashes of aggregate materials during loading and unloading.
◾ Use hearing protection if needed to guard ag ainst excessive noise exposure during cement loading/unloading and while using pneuma tic chippers inside truck mixer drums. 

# Falling Objects Hazard: Workers may be hit by falling objects from conveyor belt systems, elevators or concre te block stacking equipment. Solutions:

◾ Avoid working beneath cuber elevators, conveyor belts and stacker/destacker machinery.
◾ Stack and store materials properly tolimit the risk of falling objects.
◾ Wear eye protection when chipping and cleaning forms, products or mixers. 

# Poor Ergonomics

Confined Spaces

Vehicles

Other Hazards Page 3 of 10 Worker Safety Series - Concrete Manufacturin g

8 /4 /201 5 https://www.osha.gov/Publicati ons/concrete_manufacturing.htm l◾ Welding operations can lead to flash burns.
◾ Makeshift ladders, platforms and stairs with improper or no guardrails make falls more likely.
◾ Workers can also be injured by fa lling concrete forms if the forms ar e improperly chocked, braced or

cribbed.

◾ Be sure that trucks and other vehicles are in go od working order, includin g audible back-up warning

signals, before operating them.
◾ Avoid overloading hoists , cranes and forklifts.

◾ Be sure that form work, casting and stressing op erations are adequately braced and chocked to

avoid sudden release of materials.
◾ Make certain that rigging is in place to protect against falling objects and materials during hoisting

and stacking procedures.
◾ Do not walk or work under overhead loads. 

# Worker Safety Tips General Precautions

◾ Be sure you understand how to perform all your tasks and how to use tools and equipment safely.
◾ Follow confined space procedures when cleaning and working in mixer drums, hoppers, tanks and other places with potentially ser ious mechanical hazards,

such as blades or sloping sides which may entrap employees, or atmospheric hazards, such as oxygen deficiency.
◾ Wear appropriate personal protecti ve equipment to avoid being inju red by flying or falling objects. 

# Vehicle Safety

Machine Safety

◾ Use lockout/tagout procedures to de-energize conveyors and other machinery before a ttempting to free any jams.
◾ Secure chutes and hatches to reduce injuries from swinging parts.
◾ Make sure guards are in place to protect you from moving parts of machinery and tools before you operate the equipment. 

# Overhead Hazards Page 4 of 10 Worker Safety Series - Concrete Manufacturin g

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# Think Safety Checklists The following checklists may help you takesteps to avoid hazards that cause injuri es, illnesses and fatalities. As always, be cautious and seek help if you are concerned about a potential hazard. 

# General Safety  ̈

Implement a comprehensive safety and health management system to find and fix all hazards at the worksite.  ̈

Establish a written hazard communication program to inform all employees about chem ical hazards and hazardous substances, repo rting of hazards, appropriate personal protective equipment and what to do in emergency situations.  ̈

Train workers in safe work practices and methods for all work activities, procedures and equipm ent as well as how to recognizeand respond to potential workplace hazards, including rendering first aid.  ̈

Put in place personal protective equipmen t programs. Train workers in selecting, clea ning and maintaining equipment such as re spirators, protective clothing and goggles.  ̈

Use safe work practices and ap propriate personal protective equipment for all welding, cutting and burning; handling of chemicals (e.g., moist concrete, epoxies, form release agents); an d during grinding, chipping, wirebrushing, scraping and cleaning.  ̈

Ensure that all tools and equipment -- including forklifts, cran es, hoists and rigging -- are ma intained in good working condi tion, are inspected regularly and are operated by thoroughly traine d, tested and competent workers. 

# Physical Hazards  ̈

Set up a noise control program to reduce noise sources. Incl ude sound-level measurements, audi ometric testing, training and/or hearing protection equipment.  ̈

Implement machine guarding and lockout/tago ut procedures for all equipment and machin ery servicing and/or maintenance work to prevent workers from being injured.  ̈

Establish a confined-space entry program to protect workers cleaning the insideof mixer drums, storag e bins, hoppers and othe r confined spaces. 

# Health Hazards  ̈

Avoid exposure to cement dust to prevent bronchitis and silicosis.  ̈

Prevent burns and skin and eye irritation by avoiding skin contact and eye contact with cement dust or wet cement.  ̈

Wear the appropriate personal protective equipment, su ch as gloves, boots, goggles or HEPA-filter respirators.  ̈

Avoid dusty areas and wet down work areas, asappropriate, to reduce or eliminate dust.  ̈

Use special HEPA vacuums to clean up dust instead of dry sweeping.  ̈

Reduce silica exposures during chipping, drilling and sawing of co ncrete materials with engineer ing controls, such as wet meth ods and local exhaust ventilation. 

# Fall Hazards  ̈

Identify and fix fall hazards, such as s lippery surfaces, damaged ladders and walkways , and any loose or unsteady hand- or foo tholds used to climb up and down on trucks and other equipment.  ̈

Make sure all portable ladders have safety feet and are the prop er length for the specific task. Secure them or tie them off to prevent movement.  ̈

Ensure scaffolding and walking/ working surfaces have adequate guardrails, safeaccessibility and no tripping hazards or holes. 

# Page 5 of 10 Worker Safety Series - Concrete Manufacturin g

8 /4 /201 5 https://www.osha.gov/Publicati ons/concrete_manufacturing.htm lConfined Space Downloadable electronic ad visor software (1997), 2MB. This software guides the user in identifying confined spaces and protecting worker s who enter them. http://www.dol.gov/elaws/confined.htm Control of Hazardous Energy (Lockout/Tagout) OSHA Publication 3120 ( 2002), 174KB PDF, 45 pages. This booklet provides guidance on protecting wo rkers against unexpected energy releases from mechanical and electrical equipment. http://www.osha.gov/Pu blications/osha3120.pdf Lockout/Tagout e-Tool Interactive online training program (1999). This e-Tool offers an overview of OSHA's Lockout/ Tagout standard, including interactive case studies. http://www.osha.gov/dts/os ta/lototraining/index.html Materials Handling and Storage OSHA Publication 2226 ( 2002), 559KB PDF, 41 pages. This booklet outlines OSHA requirem ents covering handling and storing materials, focusing on forklift safety and ergonomics. http://www.osha.gov/Pu blications/osha2236.pdf Permit-Required Confined Spaces OSHA Publication 3138 ( 2004), 486KB PDF, 22 pages. This booklet covers highlights of th e OSHA standard for confined spaces. http://www.osha.gov/Pu blications/osha3138.html Safeguarding Equipment and Protecting Workers from Amputations OSHA Publication 3071 (2001) , 1.2MB PDF, 78 pages. This booklet offers guidance on machine guarding and ot her safe practices to reduce the risk of amputations. http://www.osha.gov/Pu blications/osha3170.pdf Sling Safety OSHA Publication 3072 ( 1996), 866KB PDF, 28 pages. This booklet covers all aspects of sling safety. http://www.osha.gov/Pu blications/osha3072.pdf Stairways and Ladders OSHA Publication 3124 ( 2003), 155KB PDF, 15 pages. This booklet covers safety issues related to both fixed and movable stairs and ladders. http://www.osha.gov/Pu blications/osha3124.pdf 

# Ergonomics 

Implement appropriate work practi ces and/or controls to help re duce or eliminate potential back injuries from twisting, turnin g, lifting, awkward postures and whole body vibration. 

Train workers in appropriate mechanical and manual materials hand ling techniques and safety proced ures to help reduce or elimi nate musculoskeletal injuries. 

Provide dollies, handtrucks and conveyors to help minimize, reduce or eliminate the need to bend and lift. 

# Concrete Safety & Health Resources Most resource materials can be found on the OSHA website at www.osha.gov 

# Physical Hazards

Health Hazards Crystalline Silica Exposure Card for General Industry OSHA Publication 3176 (2003), 37K B PDF; OSHA Publication 3178 (Spanish) (2003), 42KB PDF. This laminated pocket card offe rs workers a concise summary of silica health haza rds and lists precautions to take to limit exp osure. http://www.osha.gov/Pu blications/osha3176.pdf http://www.osha.gov/Pu blications/osha3178.pdf Crystalline Silica OSHA Fact Sheet (2002), 52KB PDF, 2 pages, also in Spanish (2003). This Fact Sheet highlights the hazards of silicaand provides guidance on preventing exposures. http://www.osha.gov/OshDoc/data_Ge neral_Facts/crystalline-factsheet.pdf http://www.osha.gov/Os hDoc/data_General_Fact s/crystalline-spanish.pdf 

# Page 6 of 10 Worker Safety Series - Concrete Manufacturin g

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# Voluntary Protection Programs OSHA recognizes worksites with exce llent safety and health manageme nt systems through its Voluntary Protection Programs (VPP). These model worksites are willing to share their expertise and many are available to mentor other businesses. For further information on how VPP participants can help you, contact the VPP manager in your OS HA Regional Office (see www.osha.go v for listings) or the Voluntary Protection Programs Participants' Association, 7600-E Leesburg Pike, Suite 440, Falls Church, VA 22043, telephone (703) 761-1146. 

# Alliance Program Alliances enable organizations comm itted to workplace safety and heal th to collaboratewith OSHA to prevent injuries and illnesse s in the workplace. Two of OSHA's nation al Alliances have an impact on the concrete manufacturing industry. Silica e-Tool Downloadable electronic software (1998). This e-Tool describes the hazards of silica and offers guidance on protecting workers. http://www.osha.gov/dsg/ etools/silica/index.html Hazard Communication Guidelines for Compliance OSHA Publication 3111 ( 2000), 112KB PDF, 33 pages. This booklet provides an overview of OSHA's Hazard Communi cation standard and gives specific guidance on compliance. http://www.osha.gov/Pu blications/osha3111.pdf Hearing Conservation OSHA Publication 3074 ( 2002), 157KB PDF, 32 pages. The booklet explains how to establish an effective hear ing conservation program that meets OSHA requirements. http://www.osha.gov/Pu blications/osha3074.pdf Personal Protective Equipment OSHA Publication 3151 ( 2004), 629KB PDF, 46 pages. This booklet offers guidance on when and how to use personal protective equipment to guard against occupati onal injuries and il lnesses. http://www.osha.gov/Pu blications/osha3151.pdf Respiratory Protection OSHA Publication 3079 ( 2002), 273KB PDF, 42 pages. This booklet outlines OSHA requir ements on respiratory protection and offers guid ance on establishing an effective respiratory protection program. http://www.osha.gov/Pu blications/osha3079.pdf Respiratory Protection e-Tool Downloadable electronic software (1998). This e-Tool enables users to dete rmine whether they need to establish a respirator y protection program and what type of respira tors to use. http://www.osha.gov/SLTC/eto ols/respiratory/index.html Small Entity Compliance Guide for OSHA's Respiratory Protection Standard OSHA (1999), 706KB PDF, 149 pages. This booklet provides help for small busi nesses seeking to meet OSHA requiremen ts for respiratory protection programs. http://www.osha.gov/Public ations/secgrev-current.pdf 

# NIOSH Materials The National Institute for Occupational Safe ty and Health (NIOSH) offers many useful publications available on its website at h ttp://www.cdc.gov/niosh Comprehensive Safety Recommendations for the Precast Concrete Products Industry. DHHS (NIOSH) Publication No. 84-103 (1984). Elements of Ergonomics Programs: A Primer Based on Workplace Evaluations of Musculoskeletal Disorders. DHHS (NIOSH) Publication No. 97- 117 (1997). NIOSH Hazard Review: Health Effects of Occupation al Exposure to Respirable Crystalline Silica. DHHS (NIOSH) Publication No. 2002-129 (April 2002). NIOSH Alert - Preventing Worker Deaths from Uncontrolled Release of Electrical, Mechanical, and Other Types of Hazardous Energy . DHHS (NIOSH) Publication No. 99-110 (August 1999). 

# Other Sources Ready Mixed Concrete Truck Drivers:Work-Related Hazards and Recommendations for Controls, Nancy Clark, Jonathan Dropkin and Lee Kaplan, Mt. Sinai - Irving J. Selikoff Center for Occupational and Environmental Medicine (S ept. 2001), available at http://www.elcosh. org 

# Concrete Industry Cooperative Programs Page 7 of 10 Worker Safety Series - Concrete Manufacturin g

8 /4 /201 5 https://www.osha.gov/Publicati ons/concrete_manufacturing.htm lAfter two years of preparation, Oldcastle applied for VPP recognition. OSHA eval uators spent four days assessing the facility. Their onsite visit included an opening and closing confer ence, employee interviews, industrial hygiene surveys and a complete evaluation of the site's safety and health management system. One of the highlights of Oldcastle' s program, according to Norman R. Deitch, OSHA's New York VPP Manager and the VPP Team Leader, was the company' s effort to involve Spanish-speaking employees. Oldcastle also received high marks for its extensive use of digital photos to record unsafe conditions and the results of corrective actions for worker training. Mason Contractors Association of America Reducing hazards related to wall bracing, fa lls, scaffolding and forklifts is the focus of OSHA's A lliance with the Mason Contractors Association of America. The joint effort will include developing educat ion and training programs on these issues as well as developing and disseminating ca se studies illustrating the business value of safety and health. American Concrete Pipe Association OSHA's Alliance with the American Concrete Pipe Association (ACPA) focuses on redu cing and preventing exposure to confined spac e hazards. Under this Alliance, OSHA and ACPA will develop and dissemi nate outreach materials, wo rk together on eTools and participate in other efforts to reduce injuries or illnesses associated with confined space hazards. 

# Consultation Every state offers a free, onsite consultati on program to help small employers find and fix hazards and establish effective saf ety and health management systems. Funded primarily by OSHA, consultati on is provided at no cost to small empl oyers and is delivered by state authoritiesthrough professional safety and health consultants. More information on OSHA's Consultation Program appears on the agency's website at www.osha.gov. 

# A Success Story NY Concrete Maker Improves Safety, Cuts Costs Precast concrete manufacturer Oldcastle Prec ast's Manchester New York Division reduced its occupational injury and illness rate by 75 percent in three years. The Manchester facility cut its recordable injuries from 12 in the first year to ju st one in the third year. Oldca stle experienced this incredible success by establishing a safety and health management system good enough to make it the first precast concrete faci lity to join OSHA's Merit Voluntary Protection Program (VPP). 

# Changing Culture The process began when CRH, a multinational conglomerate that manufactur es construction materials wo rldwide, sent new managers to the Building Systems Division of Oldcastle. The new managers brought cultural change and a renewed commitment to safe ty and health to the Manchester site. Managers came to know all employ ees on a first-name basis. They encouraged empl oyees to ask questions and voice any safety conc erns so that management could address them immediately. The managersemphasized the importance of employees as a company asset and made clear that empl oyee participation is key to eliminating hazards and reduci ng employee injuries and illnesses. "Having a safe work environment is just good business," according to the division's ge neral manager. "We need to make the neces sary commitment to safety at all levels of the company, and we are resp onsible to follow through with the safest ro ute, no matter what the cost," he explain ed. In the process, Oldcastle learned that safety investments pa y for themselves, time and again. 

# Aiming for VPP Oldcastle decided to aim for VPP recognitio n, knowing that working toward this goal would drive the facility toward excellence. Typically, injury and illness rates for VPP sites are 51 percent below industry norms. To qualify, Ol dcastle had to submit an application explaining the site's saf ety and health management system. Then OSHA examined the company's safety records, progra ms and history, and conducted a detailed onsite review. Once in the program, Oldcastle had to undergo periodic review s to maintain its status. To improve its safety program to qualify for VPP, Oldcastle set objectives and provided the necessary resources to accomplish t hem; they performed daily facility inspections and correcte d any problems; and they informed employees, vend ors and contractors of the program's status t hroughout the process. "We knew we had to boost existing programs an d initiate new ones to comply. We knew ou r efforts would make our company a safer plac e to work an d that was our goal," noted Oldcastle's safety manager. 

# Applying for VPP Page 8 of 10 Worker Safety Series - Concrete Manufacturin g

8 /4 /201 5 https://www.osha.gov/Publicati ons/concrete_manufacturing.htm lUnder the VPP, Merit worksites are recognized as having the potential and commitment to achieve Star status within three years. Oldcastle's goal is to reac h Star status within twelvemonths. According to the safety manager, "This achievement is looked upon by Oldcastle as a positive step in achieving a safe workplace for our employees and will only further ai d us in ensuring the co mplete safety of our workplace." Additional information about OSHA's Voluntary Protection Programs is available on the agency's website at www.osha.gov, from regional OSHA VPP managers or local OSHA offices. The Voluntary Protection Programs Participants' Association (www.vpppa.o rg ) administers a mentoring program for those worksites considering participation.

Oldcastle Precast's Manchester New York Division. 

# Continuing to Improve For the precast concrete industry (SIC 3272) in 2000, the nonfatal occupational inju ry and illness incidence rate was 13.7 per 100 full-time workers. When Oldcastle applied for VPP, its rate was 13.4. Now it is 2.0. Oldc astle found that reducing worker injuries and illnesses is not only the moral and humanitarian thing to do, but it also reduces costs associated with workpl ace accidents while increasing the division's competitiveness. Oldcastle's Accident Prevention Program remains effective becaus e everyone - the general manager, department managers, supervis ors, employees and the safety manager - takes a personal interest in accident prevention. Every effort is made to ensure that every worker knows, unde rstands and observes the requirements of applicable la ws, regulations and standards. 

# Giving Employees Credit Oldcastle's plant manager credits employees on the shop floor. "We could be the best managers in the world, but the men on the front line need to embrace the safety culture," he observed. The Manchester facility manufactures and in stalls hollowcore plank and precast concrete structural systems throughout Western N ew York. Some of the more than 2.58 million square feet of precast prod ucts weigh in excess of 25 tons each. The facility's sales manager related, "Eithe r you make precast concrete pieces safely, or you don't make them for very long." Oldcastle's safety manager spearheaded the division's commitment to safety and took charge of the VPP application process. She credits the plant employees for their hard work and continued de dication to their safety program. 

# Reaching for Star

Employers are responsible for providing a sa fe and healthful workplace for their employ ees. OSHA's role is to assure the safety and health of America's workers by setting and enforcing standards; providing training, outreach, and educatio n; establishing partnerships; and encoura ging continual improvement in workplace safety and health. This informational book let provides a general overview of a particular topic related to OSHA standards. It does not alter or de termine compliance responsibilities in OSHA standards or the Occupational Safety and Health Act of 1970. Because interpretations an d enforcement p olicy may change over time, you should consult current OSHA admini strative interpretations and decisions by the Occupational Safety and Health Review Commission and the Courts for additional guidance on OSHA compliance requirements. This publication is in the pub lic domain and may be reproduce d, fully or partially, without perm ission. Source credit is requested but not required. This information is available tosensory impaired individuals upon request. Vo ice phone: (202) 693-1999; teletypewriter (TTY) n umber: (877) 889-5627. Occupational Safety and

Health Administration U.S. Department of Labor www.osha.gov * Accessibility Assistance: Contact OSHA's Office of Communic ations at (202) 693-1999 for assi stance accessin g PDF documents. Freedom of Information Act | Privacy & Secu rity Statement | Disclaimers | Import ant Web Site Notices | International | Contact Us U.S. Department of Labor | Occupational Safety & He alth Administration | 200 Consti tution Ave., NW, Washington, DC 20210 Telephone: 800-321-OSHA (6742) | TTY www.OSHA.gov 

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# Page 10 of 10 Worker Safety Series - Concrete Manufacturin g

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