Cladding Safe Work Method Statement

Cutting fibre cement products generates respirable crystalline silica dust requiring strict control measures. Mandatory wet cutting using continuous water spray to cutting blade is required for all power tool cuts. Water binds silica dust preventing airborne dispersion and respiratory exposure. For straight cuts, use guillotine or shears which generate minimal dust. Score and snap breaking is acceptable for simple cuts where quality permits. Dry cutting of fibre cement is prohibited under WHS regulations due to extreme silica exposure. Even with wet cutting, workers must wear minimum P2 respirators during cutting activities as some dust generation still occurs. Conduct atmospheric monitoring measuring respirable crystalline silica concentrations during cutting verifying levels remain below workplace exposure standard of 0.05 mg/m³. Workers with regular fibre cement cutting exposure require annual health surveillance including respiratory function testing and chest X-rays monitoring for silicosis development. Clean up cutting waste using wet methods - never dry sweep or use compressed air which re-suspends dust. All fibre cement cutting must occur outdoors or in well-ventilated areas maximising dust dispersal. These requirements reflect serious health consequences of silica exposure and recent regulatory focus following increased silicosis cases in construction.

Wind speed limits for cladding work depend on building height, material size, and access equipment type. For scaffold-based cladding work, typical maximum wind speed is 40 km/h when handling sheet materials exceeding 1.2 metres in any dimension. Reduce this limit to 30 km/h when working above 10 metres height or handling materials exceeding 2.4 metres as larger sheets act as sails and wind speed increases with elevation. For lightweight metal cladding panels, further reduce limits to 25 km/h as these materials catch wind readily. Gusty conditions are more hazardous than steady wind - even if maximum gusts remain below absolute limits, consistent strong gusts make material control unsafe requiring work cessation. Monitor wind using calibrated anemometer measuring at work height and ground level. Wind at scaffold platforms is typically 20-30% higher than ground measurements. Cease work when sustained wind approaches limits or when workers report difficulty controlling materials regardless of measured speed. Check weather forecast before commencing work - do not start if winds forecast to exceed limits during anticipated work period. Lower loose materials to ground and secure scaffold when ceasing work due to wind. These conservative limits protect workers from destabilisation, prevent material damage from wind-torn sheets, eliminate dropped object hazards from materials blown from work areas, and reduce musculoskeletal injury from excessive force required to control materials in wind.

Scaffolding used for cladding work must be inspected and tagged by competent person before first use and after any modifications, after incidents affecting scaffold integrity, and at regular intervals not exceeding 30 days per AS/NZS 1576 requirements. Competent person conducting inspection must have specific scaffold inspection training and experience understanding structural requirements and hazard identification. Inspection checks scaffold design is appropriate for intended loads including workers, materials, and equipment; all components are serviceable without damage, excessive wear, or deterioration; base plates are stable on adequate foundations with appropriate sole boards if required; vertical components are plumb and bracing is complete and properly connected; scaffold boards are adequate thickness, properly overlapped (150-300mm), secured preventing displacement, and not damaged; guardrails are complete on all platforms exceeding 2 metres height with top rail minimum 900mm, mid-rail, and toe boards; access to platforms is via approved ladder or stair systems - climbing scaffold frames is prohibited; and scaffold is tied to building structure at intervals per design preventing overturning. After inspection, competent person attaches tag to scaffold showing inspection date, competent person identification, maximum load capacity, and next inspection due date. Only use scaffold displaying current inspection tag. Workers should conduct daily visual check before use verifying no obvious defects, damage, or modifications since inspection but this does not replace formal competent person inspection and tagging. Report any scaffold defects or concerns to supervisor immediately - do not use damaged scaffold.

Manual handling protocols for cladding work should address repetitive lifting of materials weighing 10-40kg creating cumulative musculoskeletal injury risk. Implement mechanical lifting aids including gin wheels, rope and pulley systems, or material hoists for vertical transfer of materials from ground to scaffold platforms eliminating manual carrying of materials up ladders or scaffold systems. Use platform trolleys for horizontal movement of materials along scaffold decks. Limit manual handling to final positioning during installation rather than transport. Implement two-person lift protocol for materials exceeding 15kg or awkward dimensions - never permit single-person lifting of full fibre cement sheets or metal panels exceeding 2.4 metres. Train workers in correct manual handling technique including keeping load close to body, maintaining neutral spine position, lifting with legs not back, and avoiding twisting during lifts. Design work sequence to minimise handling frequency - position materials on scaffold near installation location reducing carrying distance. Limit material quantities on scaffold to immediate requirements preventing accumulation requiring re-handling. Rotate workers between different tasks varying muscle group loading - alternate between base level installation, elevated installation, and material preparation work. Schedule regular breaks every 2 hours during sustained manual handling work allowing muscle recovery. Provide ergonomic tools reducing physical demands - use cordless tools eliminating heavy power leads, use lightweight ladders for temporary access, and provide knee pads for floor-level work reducing joint loading.

Exclusion zones below cladding work areas prevent ground personnel access beneath elevated work protecting from dropped object hazards. Establish exclusion zones extending minimum 2 metres beyond building perimeter on all sides with active cladding work above. Increase zone to 4 metres when working above 10 metres height or during high-wind conditions when materials could be blown beyond normal fall paths. Install physical barriers using barrier fencing, safety barriers, or weighted barriers rather than relying on tape or painted lines which provide no physical prevention. Install warning signage on all approach routes: 'OVERHEAD WORK - KEEP OUT - CLADDING INSTALLATION ABOVE'. Maintain exclusion zones throughout all work periods including breaks when materials remain on scaffold presenting falling hazards. Do not remove barriers overnight or on weekends if scaffold remains loaded with materials. Assign ground spotter during active material handling and installation monitoring zones and preventing unauthorised entry. Coordinate with other site trades providing alternative access routes avoiding areas below cladding work. For public footpaths or roadways adjacent to building, install overhead protection such as hoarding, scaffolding fans, or catch platforms providing secondary protection as exclusion zones may be inadequate when public access cannot be fully controlled. Exclusion zone requirements recognise severe consequences of dropped object impacts - even small tools or fasteners become lethal projectiles when falling from height. These zones protect not only project workers but also public, visitors, and delivery personnel who may be unfamiliar with site hazards.