Safe Work Method Statement

Concrete Grinding and Polishing

Comprehensive Australian WHS Compliant SWMS

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Comprehensive safety procedures for concrete grinding and polishing operations including diamond grinding, surface finishing, and polishing work. This SWMS addresses critical hazards like silica dust inhalation, vibration injuries, and equipment operation with Australian WHS compliance requirements.

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Overview

What this SWMS covers

Concrete grinding and polishing involves mechanical treatment of concrete surfaces using diamond-embedded grinding tools and polishing equipment to achieve smooth, hard-wearing finishes. This includes rough grinding to remove surface irregularities, fine grinding for surface preparation, densifying with chemical hardeners, and polishing to achieve desired gloss levels. Work is performed using walk-behind or ride-on grinding machines, hand-held grinders, and polishing equipment in various construction and renovation settings. Operations generate respirable crystalline silica dust and high vibration levels requiring comprehensive control measures.

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Why this SWMS matters

Concrete grinding and polishing presents severe occupational health risks including respirable crystalline silica (RCS) dust causing silicosis and lung cancer, hand-arm vibration syndrome from prolonged grinder use, and noise-induced hearing loss from equipment operation. According to Safe Work Australia, construction workers have elevated silica exposure risks, and vibration injuries affect thousands annually. This SWMS ensures compliance with the Work Health and Safety Act 2011 and the Managing Respirable Crystalline Silica Code of Practice 2022. Implementation prevents chronic diseases, protects workers from irreversible health damage, and ensures high-quality surface finishes while demonstrating PCBUs' duty of care.

Reinforce licensing, insurance, and regulator expectations for Concrete Grinding and Polishing Safe Work Method Statement crews before they mobilise.

Hazard identification

Surface the critical risks tied to this work scope and communicate them to every worker.

Risk register

Silica Dust Inhalation

high

Grinding and polishing concrete releases respirable crystalline silica particles that can cause silicosis, lung cancer, and other respiratory diseases when inhaled. Concrete contains 25-70% crystalline silica depending on mix design and grinding generates fine airborne particles.

Consequence: Chronic respiratory diseases, lung cancer, reduced lung function, and premature death from silica-related diseases.

Hand-Arm Vibration Syndrome

high

Prolonged use of grinding and polishing equipment transmits harmful vibration through hands and arms, causing vascular and neurological damage, loss of sensation, and reduced grip strength in operators.

Consequence: Permanent nerve damage, loss of manual dexterity, chronic pain, and inability to perform fine motor tasks.

Noise Exposure

medium

Grinding and polishing equipment generates high noise levels (90-110 dB) that can cause temporary or permanent hearing loss without proper protection and controls.

Consequence: Noise-induced hearing loss, tinnitus, communication difficulties, and increased accident risk from inability to hear warnings.

Flying Debris and Particles

medium

Grinding operations can propel concrete particles, dust, and diamond abrasives at high speeds, creating impact hazards to eyes and skin during operation.

Consequence: Eye injuries, cuts, abrasions, and potential blindness from high-speed particle impacts.

Electrical Hazards

medium

Power tools and grinding equipment present risks of electric shock, particularly when working with water suppression systems or in damp environments with damaged cords.

Consequence: Electric shock, burns, cardiac arrest, and death from electrocution.

Ergonomic Injuries

medium

Prolonged standing, awkward postures, and repetitive movements during grinding operations can cause musculoskeletal injuries including back strain and shoulder problems.

Consequence: Back injuries, shoulder strain, repetitive strain injuries, and long-term musculoskeletal conditions.

Control measures

Deploy layered controls aligned to the hierarchy of hazard management.

Implementation guide

Integrated Water Suppression Systems

Engineering

Implement integrated water delivery systems on grinding equipment that continuously supply water to cutting surfaces to suppress silica dust generation and capture airborne particles at the source.

Implementation

1. Install water delivery systems on all grinding and polishing equipment 2. Ensure continuous water flow during all cutting and grinding operations 3. Use water recycling systems to minimize water usage and waste 4. Monitor water system performance and maintain proper flow rates 5. Train operators on water system operation and troubleshooting 6. Position water nozzles to effectively wet cutting surfaces

HEPA Dust Collection Systems

Engineering

Utilize high-efficiency particulate air (HEPA) vacuum systems rated M-Class or H-Class to capture silica dust at the source and prevent airborne dispersion during grinding operations.

Implementation

1. Use vacuum systems rated for silica dust collection (M or H-Class) 2. Ensure proper hose connections and vacuum nozzle positioning 3. Position vacuum nozzles close to grinding surfaces 4. Maintain vacuum system filters and change regularly 5. Empty vacuum systems in controlled areas to prevent dust release 6. Conduct regular maintenance and filter replacement schedules

Anti-Vibration Equipment and Practices

Engineering

Select low-vibration grinding equipment and implement vibration-dampening measures to reduce hand-arm vibration exposure and prevent vibration injuries.

Implementation

1. Choose equipment with vibration-dampening features and handles 2. Use anti-vibration gloves rated for grinding operations 3. Implement work rotation between high and low vibration tasks 4. Maintain equipment to minimize vibration through proper servicing 5. Monitor vibration exposure levels using vibration meters 6. Provide vibration-free rest periods for operators

Air Quality Monitoring and Exposure Control

Administrative

Conduct regular air quality monitoring for respirable crystalline silica and implement exposure controls based on monitoring results and regulatory requirements.

Implementation

1. Test concrete silica content before commencing work 2. Monitor airborne silica levels during grinding operations 3. Implement additional controls when exposure levels approach limits 4. Keep detailed exposure monitoring records 5. Conduct health monitoring for exposed workers 6. Review and update control measures based on monitoring data

Personal Protective Equipment

PPE

Provide comprehensive PPE for silica dust, vibration, noise, and impact protection during concrete grinding and polishing operations.

Implementation

1. Issue P2 or higher respiratory protection for silica work 2. Provide anti-vibration gloves for equipment operation 3. Supply hearing protection rated for high noise levels 4. Ensure safety glasses with side protection and anti-fog coating 5. Provide steel-capped safety boots with good grip 6. Supply long pants, long sleeves, and high-visibility vests

Equipment Maintenance and Inspection

Administrative

Maintain all grinding and polishing equipment in safe working condition and conduct regular inspections to prevent mechanical failures and ensure effective dust control.

Implementation

1. Inspect all equipment before each use for safety features 2. Check dust control systems and water suppression functionality 3. Verify electrical safety and cord condition 4. Maintain cutting tools and replace worn diamond segments 5. Test emergency stop mechanisms and safety guards 6. Document all maintenance and inspection activities

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Personal protective equipment

Respiratory Protection

Requirement: P2 particulate respirator or higher, meeting AS/NZS 1716 standards

When: Required for all concrete grinding, polishing, and dust-generating work

Anti-Vibration Gloves

Requirement: Vibration-dampening gloves with impact protection and good grip

When: Required when operating vibrating grinding and polishing equipment

Hearing Protection

Requirement: Ear muffs or plugs rated for 25-30 dB noise reduction

When: Required when operating grinding equipment over 85 dB

Safety Glasses/Goggles

Requirement: Impact-resistant eyewear meeting AS/NZS 1337 with anti-fog coating

When: Required for all grinding and debris-generating operations

Steel-Capped Safety Boots

Requirement: Boots meeting AS/NZS 2210.3 with good slip resistance

When: Required at all times on construction sites

Protective Clothing

Requirement: Long pants, long sleeves, and high-visibility vest

When: Required for all concrete grinding and polishing work

Inspections & checks

Before work starts

✓Test concrete for silica content and document results
✓Inspect all grinding and polishing equipment for safety features
✓Verify dust control systems and water suppression are operational
✓Check electrical safety of power tools and extension cords
✓Assess ventilation requirements for enclosed spaces
✓Confirm availability of all required PPE and spare equipment
✓Review emergency procedures and evacuation routes
✓Check weather conditions and site access for equipment movement

During work

✓Monitor airborne silica dust levels continuously
✓Check dust control systems remain effective during operations
✓Inspect equipment for vibration levels and overheating
✓Verify PPE condition and proper usage by all workers
✓Monitor noise levels and hearing protection compliance
✓Check for signs of fatigue in operators during extended work
✓Ensure proper containment of slurry and waste materials
✓Monitor vibration exposure times and implement rotation as needed

After work

✓Inspect completed surface for required profile and finish quality
✓Check all equipment for damage and clean thoroughly
✓Verify proper disposal of silica-contaminated waste and slurry
✓Document any incidents or near-misses during operations
✓Conduct equipment maintenance and store safely
✓Clean work area and remove all debris and slurry
✓Complete exposure monitoring and documentation
✓Review work procedures for improvement opportunities

Step-by-step work procedure

Give supervisors and crews a clear, auditable sequence for the task.

Field ready

Site Assessment and Equipment Setup

Conduct comprehensive site evaluation, test silica content, and set up grinding equipment with dust control systems. Assess site conditions, access points, and establish safety controls for the grinding operation.

Safety considerations

Identify all silica sources and ensure adequate dust control measures are in place. Verify electrical safety and emergency access routes.

Surface Preparation and Cleaning

Prepare the concrete surface by removing loose debris, cleaning contaminants, and ensuring the surface is ready for grinding operations. Use appropriate cleaning methods without generating excessive dust.

Safety considerations

Use wet cleaning methods to control dust. Wear appropriate PPE during cleaning and ensure proper waste containment.

Grinding Operations

Perform mechanical grinding operations using appropriate grit diamond tools with continuous water suppression and dust collection. Work systematically across the surface achieving required profile.

Safety considerations

Maintain continuous dust and vibration controls. Monitor equipment temperature and take regular breaks to prevent hand-arm vibration syndrome.

Polishing and Finishing Operations

Apply polishing compounds and perform finishing operations using progressively finer grits to achieve the desired surface gloss and hardness. Monitor surface condition throughout the process.

Safety considerations

Ensure proper ventilation during polishing compound application. Maintain dust control measures and monitor for equipment overheating.

Surface Quality Control and Testing

Measure surface profile, gloss level, and flatness using appropriate testing equipment. Verify the finished surface meets specification requirements and client expectations.

Safety considerations

Use testing equipment safely and avoid creating additional hazards. Ensure measurement areas are clean and free of slurry.

Cleanup and Equipment Maintenance

Clean work area thoroughly, dispose of silica-contaminated waste according to regulations, and perform equipment maintenance. Clean and store all tools and equipment safely.

Safety considerations

Handle silica-contaminated waste as hazardous material. Ensure proper containment to prevent environmental contamination and worker exposure.

Documentation and Review

Complete all required documentation including exposure monitoring records, equipment inspections, and work completion reports. Review procedures for continuous improvement.

Safety considerations

Ensure all documentation is completed accurately and stored securely for regulatory compliance.

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Frequently asked questions

What is the workplace exposure standard for respirable crystalline silica during grinding?

The Australian workplace exposure standard for respirable crystalline silica (RCS) is 0.05 mg/m³ over an eight-hour time-weighted average. This limit must not be exceeded during concrete grinding operations.

How can silica dust be controlled during concrete grinding?

Silica dust can be controlled through integrated water delivery systems that continuously wet the cutting surface and HEPA vacuum dust collection systems. Respiratory protection is required when engineering controls cannot fully eliminate exposure.

What are the vibration exposure limits for grinding tools?

The exposure action value for hand-arm vibration is 2.5 m/s² A(8), and the exposure limit value is 5.0 m/s² A(8). Controls must be implemented to ensure workers are not exposed above the limit value.

How often should grinding equipment be inspected?

Equipment should be inspected before each use, with formal documented inspections conducted daily. Vibration levels, dust control systems, electrical safety, and mechanical integrity must be checked regularly.

What type of respiratory protection is required for concrete grinding?

A minimum P2 particulate respirator is required, but higher protection (P3) may be needed depending on silica concentration and ventilation effectiveness. Full-face respirators with P3 filters are recommended for high dust conditions.

How should slurry and silica waste be disposed of?

Silica-contaminated slurry and waste must be contained to prevent dust release, bagged securely, and disposed of through licensed waste management services following local environmental and WHS regulations.

Overview

Concrete grinding and polishing involves mechanical surface treatment using diamond-embedded grinding tools to achieve smooth, durable concrete surfaces. This work includes rough grinding, fine grinding, densifying, and polishing operations performed on concrete floors and surfaces. Operations are commonly performed in industrial facilities, retail spaces, warehouses, and residential properties requiring specialized equipment and generates significant dust and vibration hazards.

Why This SWMS Matters

Concrete grinding and polishing presents severe occupational health risks including silica dust inhalation causing silicosis and lung cancer, hand-arm vibration syndrome from grinding tools, and noise-induced hearing loss. Australian WHS data shows construction workers face elevated risks from silica exposure and vibration injuries affecting thousands annually. This SWMS ensures compliance with the Work Health and Safety Act 2011 and the Managing Respirable Crystalline Silica Code of Practice 2022. Implementation prevents chronic diseases, protects workers from irreversible health damage, and ensures quality surface finishing while demonstrating PCBUs' duty of care.

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