Concrete is one of the most widely used construction materials in the world, but working with concrete can expose workers to serious safety and health hazards if proper precautions are not followed. Concrete work takes place in many phases of construction including mixing, pouring, pumping, finishing, cutting, demolition, and cleanup activities.
Workers involved in concrete construction may face hazards such as:
* skin burns and irritation from wet cement
* eye injuries from splashes and airborne dust
* respiratory hazards from cement and silica dust
* slips, trips, and falls on wet or uneven surfaces
* struck-by and caught-in hazards from equipment and moving materials
* strains and sprains from lifting and repetitive work
OSHA 1926 Subpart Q provides the specific standards for concrete including requirements for equipment and tools, cast-in-place concrete, formwork, precast concrete, lift-slab operations and masonry construction.
Hazards of Concrete and Cement
Concrete contains materials that can be harmful to workers during handling and placement activities.
Hazardous materials commonly associated with concrete include:
- alkaline compounds such as lime (calcium oxide) that can burn or damage skin
- crystalline silica that can damage the lungs when inhaled
- trace amounts of hexavalent chromium that may cause allergic skin reactions or respiratory sensitization
Anyone who works with concrete, cement, mortar, grout, or similar products may develop mild to severe skin irritation, eye injuries, or respiratory symptoms if exposure is not controlled.
Wet Concrete Burns
Wet concrete can cause serious chemical burns because cement is highly alkaline and absorbs moisture from the skin. Burns may develop slowly and workers sometimes do not realize the severity of the injury until hours later.
Concrete and cement products can soak through clothing, gloves, boots, and kneepads, keeping the skin in contact with the material for long periods of time.
Signs of cement burns may include:
- redness or irritation
- pain or burning sensations
- blisters
- cracked or hardened skin
Wash areas of the skin that come into contact with wet concrete using clean, cool water as soon as possible.
Silica Dust Exposure
Many concrete tasks create airborne silica dust, especially cutting, grinding, drilling, chipping, and demolition work.
Breathing respirable crystalline silica can lead to serious lung diseases including:
- silicosis
- chronic obstructive pulmonary disease (COPD)
- lung cancer
- kidney disease
Visible dust in the air should never be ignored. OSHA has specific silica exposure requirements for construction work under OSHA Standard 1926.1153.
Personal Protective Equipment for Concrete Work
Wearing the proper personal protective equipment (PPE) is critical when working with concrete materials.
Workers may need:
- alkali-resistant gloves
- waterproof boots
- long sleeves and long pants
- eye and face protection
- respiratory protection
- hearing protection during cutting or demolition operations
Gloves and Protective Clothing
Cotton or leather gloves are not recommended for direct contact with wet concrete because they absorb moisture and may hold cement against the skin.
Butyl, nitrile, or other alkali-resistant gloves are commonly recommended for concrete work.
Wear waterproof boots high enough to prevent wet concrete from entering the footwear. Tuck pant legs outside the boots instead of inside to reduce the chance of concrete collecting inside the boot.
When kneeling on fresh concrete, use waterproof kneepads or a dry board to reduce skin exposure.
Eye and Respiratory Protection
Concrete dust and splashes can cause severe eye irritation or injury.
OSHA Standard 1926.701(f) No employee shall be permitted to apply a cement, sand, and water mixture through a pneumatic hose unless the employee is wearing protective head and face equipment.
Safety glasses, goggles, or face shields may be necessary depending on the task.
When silica dust is present, workers may also need respiratory protection such as a properly selected N95, R95, or P95 respirator as part of a compliant respiratory protection program.
Controlling Concrete Dust
Reducing dust exposure is an important part of concrete safety.
Wet methods are often used to reduce airborne silica dust during cutting, drilling, grinding, and sawing operations.
Local exhaust ventilation systems and dust collection equipment can also help control airborne particles at the source.
Use HEPA-filter vacuums or wet cleanup methods instead of dry sweeping concrete dust.
Avoid eating, drinking, or using tobacco products in dusty work areas. Wash hands and exposed skin thoroughly before breaks and meals.
Lifting and Ergonomic Hazards
Concrete work is physically demanding and often involves repetitive lifting, bending, kneeling, and carrying heavy materials.
Workers may suffer:
- back injuries
- muscle strains
- shoulder injuries
- repetitive stress injuries
- fatigue-related incidents
Use proper lifting techniques and mechanical equipment such as forklifts, hoists, wheelbarrows, pallet jacks, or hand trucks whenever possible.
Avoid awkward body positions and ask for help when loads are too heavy or difficult to handle safely.
Heavy Equipment and Struck-By Hazards
Concrete construction sites often involve concrete trucks, pumps, cranes, forklifts, and loaders operating near workers.
These activities can expose workers to:
- struck-by hazards
- caught-between hazards
- crushed-by injuries
- pinch points
Only trained and authorized workers should operate heavy equipment.
Concrete Buckets and Overhead Loads
Workers should never stand or walk beneath suspended loads or elevated concrete buckets.
OSHA Standard 1926.701(e)(2) To the extent practical, elevated concrete buckets shall be routed so that no employee, or the fewest number of employees, are exposed to the hazards associated with falling concrete buckets.
Never ride on concrete buckets or suspended loads.
Mixer and Chute Hazards
Concrete mixer chutes and moving equipment parts can create pinch points and caught-in hazards.
Keep hands, fingers, and loose clothing away from moving equipment and rotating machinery.
Equipment should be inspected regularly and defective equipment removed from service until repaired.
Slip, Trip, and Fall Hazards
Concrete work areas often contain slippery surfaces, uneven ground, rebar, hoses, cords, and debris that can increase the risk of falls.
Practice good housekeeping throughout the project and maintain clean walking and working surfaces whenever possible.
Rebar Impalement Hazards
Exposed reinforcing steel can create serious impalement hazards on concrete projects.
OSHA Standard 1926.701(b) All protruding reinforcing steel, onto and into which employees could fall, shall be guarded to eliminate the hazard of impalement.
Rebar should be properly capped or guarded whenever workers could fall onto exposed steel.
Walking and Access Safety
Inspect ladders, scaffolds, walkways, and access points regularly.
Remove or correct slip hazards caused by wet concrete, mud, water, loose materials, or poor housekeeping conditions as quickly as possible.
Concrete Safety Planning
Concrete safety starts before the work begins.
Employers and workers should plan for:
- PPE requirements
- silica exposure controls
- equipment inspections
- safe lifting practices
- traffic control around equipment
- emergency response procedures
- housekeeping and cleanup
Recognizing concrete hazards early and following safe work practices can help prevent serious injuries, long-term health problems, and fatal incidents on construction sites.
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