Comprehensive SWMS for Playground Safety Surfacing Installation and Maintenance

Soft-fall Surface Removal and Installation Safe Work Method Statement

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Soft-fall surface removal and installation involves the preparation, installation, and maintenance of impact-attenuating playground safety surfacing designed to reduce injury severity from falls. This specialised landscaping work encompasses removal of deteriorated surfacing materials, base preparation, installation of various soft-fall products including rubber tiles, wet-pour rubber, synthetic turf with shock pad, bark mulch, and sand systems. This SWMS addresses the specific safety requirements for soft-fall surfacing work in accordance with Australian WHS legislation and AS 4685 playground safety standards, providing detailed hazard controls, inspection procedures, and installation methods to ensure worker safety and compliance with fall height requirements.

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Overview

What this SWMS covers

Soft-fall surface installation is a critical safety measure for playgrounds, ensuring impact-attenuating surfaces reduce injury severity when children fall from play equipment. Australian Standard AS 4685 mandates specific impact attenuation requirements based on fall heights, requiring soft-fall surfaces to meet Critical Fall Height (CFH) ratings verified through standardised testing. Landscaping contractors installing playground surfacing must understand these requirements and select appropriate materials and installation methods to achieve compliance. Soft-fall surfacing materials include loose-fill products such as bark mulch (typically 300-400mm depth), sand systems (requiring 300-450mm depth for adequate impact attenuation), and engineered wood fibre. Unitary surfaces include rubber tiles (typically 40-75mm thickness), wet-pour rubber systems (applied as two-layer systems with base and wear layers totalling 30-60mm), and synthetic turf with shock pad underlays. Each material type presents different installation requirements, performance characteristics, maintenance needs, and lifespan expectations. Removal of existing deteriorated soft-fall surfacing is frequently required before new installation, particularly when replacing non-compliant materials or worn surfaces failing impact testing. Removal work involves manual excavation using shovels and rakes for loose-fill materials, cutting and lifting for rubber tile systems, or mechanical removal using skid steers or excavators for large areas. Removed materials require appropriate disposal, with contaminated bark mulch potentially classified as contaminated soil if children's play has introduced biological contaminants. Rubber materials may be recyclable through specialist processors. Base preparation is critical for successful soft-fall installation and long-term performance. For loose-fill systems, a firm, level base with adequate drainage prevents waterlogging and material migration. Geofabric installation beneath loose-fill prevents weed growth and material loss into underlying soil. For unitary surfaces, base preparation requirements are more stringent. Wet-pour rubber systems require concrete or asphalt bases with specific surface preparation including grinding or shot-blasting to achieve adhesion. Rubber tile systems require firm, level bases capable of supporting point loads from play equipment. Installation sequencing coordinates with playground equipment installation. Soft-fall surfacing typically installs after equipment footings are constructed but may occur before or after equipment installation depending on surfacing type. Wet-pour rubber systems often install after equipment to avoid surface damage during equipment installation. Loose-fill systems can install before equipment but require replenishment after equipment installation to achieve final depths. Contractors must coordinate carefully with equipment installers to ensure optimal sequencing and protect installed surfaces from damage.

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Why this SWMS matters

Playground safety surfacing directly prevents serious injuries to children, making correct installation a critical safety and compliance issue. Safe Work Australia data indicates playground falls represent a significant proportion of childhood injuries, with inadequate impact attenuation contributing to fractures, head injuries, and other trauma. Properly installed soft-fall surfacing meeting AS 4685 requirements dramatically reduces injury severity, protecting children whilst ensuring facility operators comply with playground safety obligations. Legal liability for playground injuries falls on facility operators including councils, schools, childcare centres, and property managers. When injuries occur on playgrounds with non-compliant or poorly maintained surfacing, operators face significant legal and financial consequences. Recent Australian court cases have found operators negligent when playground surfacing failed to meet impact attenuation standards or had deteriorated beyond serviceable condition. These cases have resulted in substantial damages awards and increased insurance premiums. Comprehensive SWMS documentation for soft-fall installation provides evidence of systematic quality management and compliance focus. Worker safety during soft-fall installation involves multiple hazards requiring specific controls. Manual handling injuries from lifting heavy rubber tiles (15-25kg each), repetitive bending during loose-fill spreading, and sustained kneeling during tile installation cause musculoskeletal injuries. Chemical exposure during wet-pour rubber installation includes polyurethane binders releasing isocyanates requiring respiratory protection and skin protection. Heat stress affects workers during summer installation work, particularly when wearing full PPE for chemical protection. Sharp hand tools used for cutting rubber materials present laceration risks. Without proper hazard controls and work methods, installers suffer preventable injuries affecting their long-term health and work capacity. Environmental compliance adds complexity to soft-fall installation work. Wet-pour rubber systems contain chemicals requiring controlled application to prevent environmental contamination. Overspray and washdown water from equipment cleaning must not enter stormwater systems. Some binder chemicals have volatile organic compound (VOC) content requiring emission controls in certain jurisdictions. Bark mulch and organic materials must be weed-free to prevent introduction of declared weeds to sites. Materials sourced from interstate may require biosecurity declarations. The SWMS ensures environmental requirements are identified and incorporated into work methods. Quality assurance for soft-fall installation requires verification that installed surfaces meet AS 4685 impact attenuation requirements. This typically involves third-party testing using specialised impact testing equipment measuring Head Injury Criterion (HIC) and Gmax values at various fall heights. Testing occurs after installation completion but before playground opening. Failed tests require remedial work including additional material depth for loose-fill systems or replacement of unitary surfaces. The SWMS specifies installation quality controls, material depth verification, and compaction limits to maximise likelihood of passing impact testing, avoiding costly remedial work and project delays.

Reinforce licensing, insurance, and regulator expectations for Soft-fall Surface Removal and Installation 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

Manual Handling of Heavy Rubber Tiles and Materials

high

Rubber tile installation involves repetitive lifting and positioning of tiles weighing 15-25kg each, with large playgrounds requiring hundreds of tiles. Installers adopt sustained kneeling and bending postures during tile laying, edge trimming, and interlocking connection. Bags of adhesive and binder materials weigh up to 25kg requiring manual handling from delivery points to work areas. Rolls of synthetic turf with shock pad backing weigh 200-400kg requiring mechanical handling or team lifts. These combined manual handling demands cause lower back strain, knee joint damage, shoulder injuries, and chronic musculoskeletal disorders. The repetitive nature over extended installation periods compounds injury risk, with installers working 6-8 hour days on hands and knees during large projects.

Consequence: Acute lower back strain requiring immediate cessation of work, chronic disc degeneration from sustained poor postures, knee cartilage damage requiring surgical intervention, shoulder impingement from repetitive lifting, and long-term disability affecting work capacity and quality of life.

Isocyanate Exposure from Wet-pour Rubber Binder Systems

high

Wet-pour rubber installation uses two-component polyurethane binder systems containing methylene diphenyl diisocyanate (MDI) or toluene diisocyanate (TDI). These chemicals release vapours during mixing and application causing acute respiratory irritation, sensitisation leading to occupational asthma, and potential long-term respiratory disease. Skin contact causes dermatitis and allergic sensitisation. Once sensitised, workers may experience severe reactions from minimal future exposure, potentially ending their career in this work. Vapour generation is highest during hot weather installation when chemical reactivity increases. Enclosed or poorly ventilated playgrounds surrounded by buildings concentrate vapours in installer breathing zones. Spray application methods increase exposure compared to trowel application but offer productivity advantages.

Consequence: Acute respiratory distress including coughing, wheezing, and breathing difficulty requiring emergency medical treatment. Chronic occupational asthma requiring ongoing medication and potentially forcing career change. Chemical sensitisation causing severe allergic reactions from future minimal exposures. Dermatitis requiring medical treatment and time off work.

Heat Stress During Summer Installation Work

high

Soft-fall installation occurs predominantly outdoors in exposed playground areas with minimal shade. Summer temperatures combine with radiant heat from concrete or asphalt bases and metabolic heat from physical exertion during manual handling and installation work. Workers wearing chemical-resistant suits for wet-pour rubber application experience dramatically reduced heat dissipation, rapidly elevating core body temperature. Rubber tile installers working on hands and knees on dark rubber surfaces absorb additional radiant heat. Dehydration occurs rapidly, particularly when workers fail to recognise early heat stress symptoms or defer fluid intake during focused work. Heat stress progresses from heat exhaustion with dizziness, nausea, and reduced work capacity to potentially fatal heat stroke requiring emergency medical intervention. Installation work scheduled during January-March heatwave periods presents maximum risk, particularly in northern Australian locations.

Consequence: Heat exhaustion causing dizziness, nausea, headache, and reduced coordination increasing risk of other injuries. Heat stroke causing confusion, collapse, and potentially fatal hyperthermia requiring emergency hospitalisation. Dehydration reducing physical and cognitive performance. Chronic heat exposure increasing cardiovascular strain and long-term health impacts.

Lacerations from Cutting Tools and Material Edges

medium

Soft-fall installation requires extensive cutting of rubber tiles to fit irregular playground boundaries, equipment clearances, and drainage points. Sharp utility knives, carpet knives, and powered cutting tools present laceration risks during cutting operations and when stored in pockets or tool belts. Freshly cut rubber tiles have sharp edges requiring careful handling. Synthetic turf cutting with hooked blades causes deep lacerations if blades slip during cutting or when reaching into tool pouches. Spent blades discarded carelessly present hazards to other workers and potentially to children using completed playgrounds. Inadequate lighting during cutting operations or working in awkward positions increases the likelihood of tool contact injuries. Rushed cutting to meet project deadlines reduces attention to safe cutting techniques.

Consequence: Deep lacerations requiring medical treatment and suturing, severed tendons or nerves causing permanent hand function loss, puncture wounds from improperly stored knives, infections from contaminated cutting tools contacting wounds, and lost time injuries disrupting project schedules.

Trip Hazards from Loose Materials and Equipment

medium

Soft-fall installation creates extensive trip hazards across playground work areas. Loose-fill materials such as bark mulch and sand spread across base areas before levelling create unstable walking surfaces. Stacks of rubber tiles positioned throughout work areas obstruct pathways. Wheelbarrows, compaction equipment, mixing equipment, and material packaging create obstacles particularly when multiple installers work simultaneously. Geofabric installation leaves rolls and cutting equipment scattered across work zones. Hoses from cement mixers or wet-pour rubber spray equipment trail across work areas. Poor housekeeping during busy installation phases compounds these hazards. Workers carrying heavy materials or focused on installation quality may not observe ground conditions adequately. Trips result in falls onto hard concrete or asphalt bases before soft-fall installation is complete, or falls onto partially installed materials causing material damage requiring rework.

Consequence: Falls causing impact injuries including fractures, sprains, and soft tissue trauma. Head injuries from uncontrolled falls onto hard surfaces or equipment. Dropped materials causing foot injuries when workers trip whilst carrying heavy rubber tiles or material bags. Project delays from injured workers requiring replacement personnel unfamiliar with work sequencing.

Dust Exposure During Base Preparation and Concrete Grinding

medium

Base preparation for wet-pour rubber systems requires concrete grinding or shot-blasting to remove surface laitance and achieve required surface profile for adhesion. These processes generate respirable crystalline silica dust presenting serious long-term health risks. Even when using dust extraction equipment, some dust exposure occurs particularly when working in enclosed playground areas with inadequate air movement. Cutting existing concrete or asphalt during removal work generates additional silica dust. Dry sweeping of dust during cleanup spreads dust into air rather than controlling it. Workers may underestimate silica hazards as dust exposure does not cause immediate symptoms, unlike chemical vapours which prompt immediate concern. Prolonged silica dust exposure over years of playground installation work causes irreversible lung disease.

Consequence: Chronic silicosis (lung scarring) developing over years of exposure causing progressive breathing difficulty and reduced exercise tolerance. Increased lung cancer risk from crystalline silica exposure. Chronic obstructive pulmonary disease (COPD) requiring ongoing medical management. Acute silicosis from high-intensity exposures during inadequately controlled grinding operations.

Control measures

Deploy layered controls aligned to the hierarchy of hazard management.

Implementation guide

Mechanical Handling Equipment and Two-Person Lift Protocols

Engineering Control

Eliminate manual handling where possible by using wheelbarrows, trolleys, and material carts to transport rubber tiles, adhesive bags, and loose-fill materials from storage to work areas. Provide knee pads or kneeling mats for all workers during tile installation and provide raised work platforms where feasible for tile preparation activities. Implement mandatory two-person lifting for synthetic turf rolls, heavy equipment, and material pallets. Schedule task rotation between kneeling installation work and standing preparation work to vary muscle group loading and reduce cumulative strain. This engineering approach reduces manual handling injuries by eliminating or minimising heavy lifts and sustained awkward postures.

Implementation

1. Provide dedicated material trolleys capable of transporting 10-15 rubber tiles from storage to installation area, eliminating individual tile carrying 2. Position material storage points at maximum 20-metre intervals from installation areas to minimise carry distances 3. Supply knee pads rated to AS/NZS 4503 Type 2 for all installers, with replacements available when padding compresses below effective thickness 4. Implement 2-hour task rotation schedule alternating workers between tile laying (kneeling), tile cutting (standing at bench), and material handling 5. Use pump trucks or forklifts to position material pallets close to work areas rather than manual carrying from central storage 6. For synthetic turf rolls exceeding 50kg, mark clearly as requiring minimum 2-person lift and use mechanical lifting equipment where available 7. Schedule regular 10-minute breaks every 2 hours during extended tile laying work to perform stretching exercises

Respiratory Protection and Ventilation for Wet-pour Rubber Work

Personal Protective Equipment

Mandate full-face supplied air respirators or powered air purifying respirators (PAPR) with organic vapour and particulate filters for all workers involved in wet-pour rubber mixing and application. Standard cartridge respirators provide inadequate protection for isocyanate exposures above action levels. Conduct work during cooler morning periods when chemical reactivity and vapour generation is reduced. Implement work/rest cycles when working in chemical-resistant suits to prevent heat stress. Obtain Safety Data Sheets for all binder products and verify isocyanate content and exposure controls. This control hierarchy places primary reliance on respirator protection as isocyanate elimination is not feasible whilst using these products, though some lower-isocyanate formulations are emerging in the market.

Implementation

1. Provide full-face supplied air respirators or PAPR units with P3 filters and organic vapour cartridges rated for isocyanate service 2. Conduct fit testing for all workers before first use and annually thereafter to verify adequate seal and protection 3. Schedule wet-pour rubber work for morning periods before 11am when temperatures are lower and vapour generation reduced 4. Implement 45-minute work periods followed by 15-minute rest breaks when workers are wearing full chemical protective suits 5. Establish clean change area separated from work zone for removal of chemical-contaminated clothing and respirators 6. Maintain respirator cleaning and disinfection procedures after each use to prevent dermatitis from contaminated face seals 7. Monitor weather forecasts and cease isocyanate work when temperatures exceed 32°C due to accelerated chemical reactions 8. Provide chemical-resistant suits (Tyvek or equivalent) covering all skin surfaces to prevent dermal isocyanate exposure

Heat Stress Management and Hydration Protocols

Administrative Control

Implement heat stress monitoring using wet bulb globe temperature (WBGT) measurements or weather app monitoring during summer installation work. Establish work/rest schedules based on heat stress index with increased rest periods as temperatures rise. Provide shaded rest areas with seating and cooling facilities. Mandate hydration breaks every 30 minutes with cool water or electrolyte drinks available. Recognise that workers wearing chemical protective equipment experience 50-100% increase in heat stress compared to workers in standard clothing. Reschedule heavy physical work to cooler morning periods and lighter tasks to afternoon periods during extreme heat events. This administrative control reduces heat stress risk through work scheduling and environmental management.

Implementation

1. Monitor Bureau of Meteorology forecasts and local temperature readings at site level using digital thermometers 2. Implement High Risk work protocols when WBGT exceeds 28°C including mandatory 10-minute breaks every 30 minutes of work 3. Establish shaded rest area using marquee or existing structures with seating, iced water, and electrolyte drinks 4. Brief workers on heat stress symptoms recognition including headache, dizziness, nausea, and reduced coordination 5. Assign supervisor to monitor worker behaviour for signs of heat stress including reduced work rate, confusion, or irritability 6. Reschedule physically demanding tasks such as material delivery and base excavation to 6am-10am periods during heatwaves 7. Provide cooling vests or ice vests for workers wearing chemical protective equipment during summer work 8. Cease work entirely when forecast temperatures exceed 38°C in shade, particularly if chemical protective equipment is required

Cutting Tool Safety and Blade Management Procedures

Administrative Control

Standardise on retractable utility knives with automatic blade retraction when thumb pressure releases, eliminating fixed-blade knives from sites. Provide designated cutting boards or mats for material cutting rather than cutting on installed work or makeshift surfaces. Implement procedures for safe blade changes including blade disposal in puncture-resistant sharps containers. Brief workers on proper cutting techniques including cutting away from body, maintaining stable workpiece positioning, and using appropriate force without excessive pressure that causes blade deflection. Ensure adequate lighting at cutting stations to clearly see cutting lines and blade position. This administrative approach reduces laceration risk through equipment selection and procedural controls.

Implementation

1. Supply retractable utility knives with automatic blade retraction as standard equipment to all installers 2. Establish designated cutting station with stable work bench at comfortable standing height and adequate lighting 3. Provide purpose-built puncture-resistant sharps containers for blade disposal at cutting stations and in work vehicles 4. Train workers to inspect blades before each use and replace immediately when dull, rather than applying excessive force with dull blades 5. Implement procedure requiring placement of utility knives on bench between cuts rather than in pockets where blade may deploy 6. Brief workers to cut away from body with blade travel direction away from non-knife hand supporting material 7. Provide cut-resistant gloves rated Level 5 per AS/NZS 2161.4 for workers supporting materials during cutting operations 8. Mark material cutting lines clearly using chalk or marker before cutting to eliminate repeated measuring whilst holding sharp tools

Workplace Organisation and Housekeeping Standards

Administrative Control

Implement daily housekeeping schedules maintaining clear access pathways throughout playground work areas. Designate specific material storage zones away from main traffic routes with materials stacked stably below 1.5 metre height. Require hose and cable management using cable ramps or designated routes marked with bunting or witches hats. Establish waste collection points for packaging materials with regular clearance to skip bins. Ensure adequate lighting in work areas particularly during winter months when daylight hours are limited. This administrative control reduces trip hazard risk through systematic workplace organisation and maintenance of clear work zones.

Implementation

1. Designate material storage zones at playground perimeter clearly marked with witches hats or barrier tape 2. Stack rubber tiles maximum 1.5 metres high on stable pallets or ground surfaces, never on sloped ground 3. Assign one worker to conduct 10-minute housekeeping sweep at morning tea break and lunch break clearing pathways 4. Route hoses and electrical cables around playground perimeter rather than across main work areas where possible 5. Where cables must cross pathways, install cable ramps or cover with plywood ramps taped securely at edges 6. Provide designated waste collection cages or areas for packaging materials with scheduled clearance before overflow occurs 7. Install temporary lighting towers if work extends past 5pm during winter months to maintain minimum 200 lux illumination 8. Conduct toolbox meeting each morning including specific housekeeping responsibilities and pathway clearance checks

Dust Extraction and Wet Methods for Silica Control

Engineering Control

Use concrete grinders equipped with integrated dust extraction systems connected to H-class vacuum cleaners rated for silica dust. Implement wet grinding methods where feasible to suppress dust generation at source. Prohibit dry sweeping of concrete dust, requiring only wet mopping or HEPA-filtered vacuum collection. Provide disposable coveralls to prevent silica dust accumulation on clothing and transfer to vehicles and homes. Conduct base preparation work during periods when children and other trades are not present to minimise exposure to others. This engineering approach eliminates or minimises airborne silica dust through capture at source and wet methods preventing dust becoming airborne.

Implementation

1. Specify concrete grinders with integrated shrouded grinding heads connected to H-class extraction vacuums 2. Verify vacuum cleaners are rated H-class per AS/NZS 60335.2.69 specifically for hazardous dusts including silica 3. Conduct water spray suppression during concrete cutting operations using dedicated water supply and spray nozzles 4. Replace H-class vacuum filters according to manufacturer schedules, disposing as contaminated waste in sealed bags 5. Provide disposable coveralls for workers conducting grinding operations, disposing coveralls daily in sealed bags 6. Prohibit compressed air blowing of dust from clothing, equipment, or surfaces which disperses dust into breathing zones 7. Implement wet mopping only for dust cleanup using mops disposed as contaminated waste or laundered by specialist industrial service 8. Schedule base preparation work for periods when playground and adjacent areas are unoccupied to protect bystanders from dust exposure

Download complete control procedures

Personal protective equipment

Requirement: PAPR or supplied air system for isocyanate exposure per AS/NZS 1716

When: Mandatory during all wet-pour rubber mixing, application, and cleanup activities where isocyanate-containing binders are used

Requirement: Type 4 or Type 5 per AS/NZS 4501.2

When: During wet-pour rubber application to prevent skin contact with isocyanate binders and reactive chemicals

Requirement: Level 5 cut resistance per AS/NZS 2161.4

When: When cutting rubber tiles, synthetic turf, or handling materials with sharp edges during installation and trimming operations

Requirement: Nitrile or butyl rubber per AS/NZS 2161.10.2

When: When mixing or applying wet-pour rubber binders, adhesives, or any chemical products during installation

Requirement: Type 2 knee pads per AS/NZS 4503

When: During all tile laying, rubber installation, and floor-level work requiring sustained kneeling postures throughout installation

Requirement: Category 1 impact protection per AS/NZS 2210.3

When: Throughout all soft-fall installation activities to protect against dropped materials, equipment, and manual handling loads

Requirement: SPF 50+ sunscreen and broad-brimmed hat per cancer council guidelines

When: During all outdoor installation work with UV Index above 3, typically year-round in Australian conditions

Inspections & checks

Before work starts

  • ✓Verify playground design documentation including fall height requirements and specified soft-fall material depths or impact ratings
  • ✓Confirm base preparation is complete including adequate compaction, level surface, and drainage provisions meeting specifications
  • ✓Check geofabric installation is complete beneath loose-fill areas with adequate overlaps and secured edges preventing material loss
  • ✓Inspect concrete or asphalt bases for wet-pour rubber systems verifying surface preparation including grinding to required profile
  • ✓Verify all required materials are on site including tiles, binder components, tools, and PPE before commencing installation
  • ✓Check weather forecast confirming suitable conditions for planned work particularly temperature and rain forecast for wet-pour work
  • ✓Confirm playground equipment installation sequence to coordinate soft-fall installation timing and protect completed work
  • ✓Verify emergency facilities including first aid, eyewash station, and communication equipment are available and functional

During work

  • ✓Monitor worker manual handling techniques during tile installation intervening if unsafe lifting postures observed
  • ✓Verify two-person lift protocols are followed for heavy synthetic turf rolls and material pallets
  • ✓Check respirator seal and function during wet-pour rubber work particularly when workers report breathing difficulty or chemical odours
  • ✓Monitor heat stress symptoms including checking worker colour, coordination, and work rate during summer installation work
  • ✓Verify loose-fill material depths are achieving specified minimums using depth probe at regular intervals across installation area
  • ✓Inspect tile interlocking connections ensuring tiles are fully engaged without gaps that could present trip hazards
  • ✓Monitor housekeeping standards ensuring pathways remain clear and material stacks are stable throughout work period
  • ✓Check cutting tool condition before use verifying blade sharpness and retraction mechanisms function correctly

After work

  • ✓Measure completed loose-fill material depths at multiple locations across playground verifying minimum depth requirements achieved
  • ✓Inspect rubber tile installation for level surface, secure interlocking, and proper edge trimming without trip hazards
  • ✓Verify wet-pour rubber surface is smooth, fully cured, and free from defects before releasing for impact testing
  • ✓Conduct final cleanup removing all packaging materials, excess materials, and equipment from playground area
  • ✓Document installation date, material types, batch numbers, and installed depths for future maintenance and compliance records
  • ✓Photograph completed installation from multiple angles for quality records and future reference if issues arise
  • ✓Clean and properly store all tools and equipment with contaminated items disposed as per chemical waste protocols
  • ✓Schedule third-party impact testing to verify installed surface meets AS 4685 critical fall height requirements before playground opening

Step-by-step work procedure

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

Field ready

Site Assessment and Existing Surface Removal

Assess playground area identifying existing surfacing type, condition, and removal requirements. Photograph existing conditions documenting any hazards or non-compliant areas. If removing existing soft-fall materials, verify disposal method is appropriate for material type. Bark mulch may contain biological contaminants requiring disposal as contaminated soil. Rubber materials may be recyclable through specialist processors. Establish exclusion zones using barrier fencing to prevent unauthorised entry during work. Post signage indicating playground closed for maintenance. For loose-fill removal, use shovels and wheelbarrows to collect material. For rubber tile removal, lift tiles manually and stack on pallets for disposal or recycling. For wet-pour rubber removal, use mechanical methods such as jackhammers or grinding equipment with dust extraction. Remove all materials to base level exposing concrete, asphalt, or compacted soil base. Inspect base for damage, drainage adequacy, and level requirements.

Safety considerations

Wear appropriate PPE including dust mask (P2 minimum) during removal of dry materials. Use hearing protection during mechanical removal with powered equipment. Establish clear lifting limits for manual handling of removal materials - use wheelbarrows rather than carrying bags. Watch for hidden hazards in existing soft-fall including glass, syringes, or animal waste requiring special handling. Ensure adequate hydration during physical removal work particularly in summer conditions.

Base Preparation and Geofabric Installation

Verify base is adequately compacted to prevent future settlement causing uneven surfaces or ponding. Use plate compactor for soil bases achieving minimum 95% compaction ratio. Check base is level using laser level or string lines - maximum 1:50 gradient for drainage. For wet-pour rubber installation on concrete bases, conduct surface grinding using diamond grinding heads with dust extraction. Grind to achieve Concrete Surface Profile (CSP) rating of CSP-2 or CSP-3 providing adequate key for adhesion. For loose-fill installations, roll out geofabric across entire base area allowing 300mm overlap at joins. Secure geofabric edges using 150mm steel pins at 1-metre spacing or bury edges in trenches at playground perimeter. Cut geofabric accurately around equipment footings allowing 50mm clearance. Install edge restraints for loose-fill areas using treated timber, recycled plastic edging, or concrete edging secured with stakes or concrete backfill. Ensure edge restraints are level and sufficiently robust to contain material depths specified.

Safety considerations

Use H-class vacuum extraction during concrete grinding to control silica dust. Wear disposable coveralls during grinding work to prevent silica dust transfer to vehicles. Ensure adequate ventilation and avoid working in enclosed areas during grinding. Use mechanical assistance (plate compactor) to achieve required compaction rather than manual compaction methods. When cutting geofabric, use stable cutting surface and cut-resistant gloves to prevent lacerations. Ensure edge restraint installation uses proper PPE including safety glasses during sawing or drilling operations.

Loose-fill Material Installation and Levelling

For bark mulch or engineered wood fibre installation, calculate required volume based on area and specified depth (typically 300-400mm for fall heights up to 3 metres). Order certified compliant materials meeting AS 4685 requirements with documentation of impact testing results. Deliver materials in bulk bags or tipper trucks and position at multiple points around playground perimeter to minimise carry distances. Use wheelbarrows to distribute material across playground area working from equipment locations outward. Spread material to achieve consistent depth using rakes and shovels. Use depth probe or measuring rod at regular intervals to verify minimum depth achieved across entire area. Do not compact loose-fill materials as compaction reduces impact attenuation. Install timber edging or border definition at consistent height to maintain material containment. For sand installations, use clean washed sand of specified particle size distribution. Avoid using builder's sand which contains dust and fine particles that cement when wet.

Safety considerations

Use wheelbarrows and mechanical handling to transport materials rather than manual carrying of bags. Implement task rotation between barrowing, spreading, and levelling to vary physical demands. Wear dust masks (P2 minimum) during spreading of dry materials particularly in windy conditions. Take regular breaks during sustained physical work especially in hot conditions. Ensure adequate hydration with water stations at playground perimeter. Use gloves during rake and shovel work to prevent blisters from sustained tool use. Watch for trip hazards from loose materials and equipment during installation.

Rubber Tile System Installation

For rubber tile installation, verify base is firm, level, and dry before commencing. Confirm tile thickness specified is adequate for fall heights present based on manufacturer's impact testing certification. Commence installation from one corner or straight edge working systematically across playground area. Lay tiles following manufacturer's interlocking system - typically tongue and groove or jigsaw pattern. Ensure tiles are fully engaged with adjacent tiles without gaps. Use rubber mallet to tap tiles into position if required but avoid excessive force that could damage interlocking mechanism. Cut tiles to fit irregular boundaries using sharp utility knives on stable cutting surface - mark cutting lines accurately before cutting. For better accuracy on complex cuts, create cardboard templates. Install ramp edge tiles or bevelled edges at playground boundaries to eliminate trip hazards. For adhesive-down tiles, apply adhesive according to manufacturer specifications using notched trowel to achieve consistent coverage. Work in manageable sections allowing adequate working time before adhesive becomes unworkable.

Safety considerations

Use knee pads throughout tile installation work to protect knees during sustained kneeling. Implement task rotation every 2 hours between tile laying and tile preparation/cutting. Use cut-resistant gloves when cutting tiles to protect hands from sharp blades and cut tile edges. Ensure cutting area has adequate lighting and stable work surface. Use trolleys to transport tiles from storage to work area eliminating individual tile carrying. Take regular breaks including standing and stretching to prevent cumulative strain. Ensure adequate ventilation when using adhesives and follow manufacturer PPE requirements.

Wet-pour Rubber System Application

Wet-pour rubber installation requires specialist training and equipment. This summary provides safety overview only - refer manufacturer instructions for specific application methods. Verify base preparation is complete with required surface profile achieved and base is clean, dry, and free from contaminants. Mix rubber granules with two-component polyurethane binder according to manufacturer ratios using forced-action mixer to achieve consistent distribution. Apply base layer (typically black SBR rubber granules) using trowels, rollers, or spray equipment depending on system type. Achieve specified thickness (typically 10-25mm for base layer) across entire area maintaining consistent depth. Allow base layer to partially cure (typically 4-6 hours) before applying wear layer. Apply coloured EPDM rubber wear layer (typically 6-15mm thickness) achieving smooth, uniform surface finish free from holidays (thin spots) or raised areas. Total system thickness depends on fall height requirements - typically 30-60mm total for fall heights up to 3 metres. Maintain consistent mixing ratios throughout project - variations affect curing and performance. Monitor weather conditions carefully - temperature, humidity, and wind affect curing characteristics.

Safety considerations

This is HIGH RISK work requiring full respiratory protection (supplied air or PAPR) and chemical protective equipment. Only trained personnel with isocyanate handling experience should conduct this work. Establish exclusion zones preventing other workers and public accessing area during application and curing. Position workers upwind of application area where possible. Implement 45-minute work / 15-minute rest cycles to prevent heat stress when wearing full chemical suits. Monitor workers for signs of heat stress including reduced coordination or confusion. Ensure eyewash facilities and emergency shower access in case of chemical exposure. Have Material Safety Data Sheets immediately available. Notify emergency services of location and chemicals in use before commencing in case of emergency requiring medical response.

Quality Verification and Impact Testing Coordination

Upon completion of soft-fall installation, conduct internal quality verification before engaging third-party testing. For loose-fill systems, use depth probe at minimum 10 locations across playground measuring actual installed depth and verifying minimum specified depth is achieved at all locations. Document measurements with location photos for records. For rubber tile systems, inspect entire surface checking tiles are level, interlocking connections are secure, edges are properly finished, and no trip hazards exist at boundaries. For wet-pour rubber systems, inspect for surface defects including holidays, soft spots, or areas not fully cured. Verify surface is smooth with no sharp edges or protrusions. Engage NATA-accredited testing authority to conduct impact attenuation testing per AS 4685 requirements. Testing involves dropping instrumented headform from specified fall heights and measuring Head Injury Criterion (HIC) and Gmax values. Testing must occur at multiple locations across playground particularly areas with highest fall heights. Results must meet pass criteria (HIC <1000, Gmax <200) for all fall heights present. If testing fails, identify causes (insufficient depth, poor installation, incorrect materials) and implement remedial work before re-testing.

Safety considerations

During testing, maintain exclusion zones preventing workers and public accessing test areas as dropped headform presents impact hazards. Verify testing contractor has adequate public liability insurance and follows safe work practices. Review test results carefully - failed tests require remedial work which may involve partial or complete reinstallation at contractor cost. Ensure quality control during initial installation to maximise first-time testing success. Maintain detailed records of materials used including batch numbers, mix ratios, and supplier certifications to assist investigation if testing fails.

Final Cleanup and Handover Documentation

Conduct comprehensive site cleanup removing all packaging materials, excess materials, equipment, and tools from playground area. Collect and dispose of chemical containers from wet-pour work according to hazardous waste disposal requirements - do not place in general waste. Clean equipment used for wet-pour installation immediately after use before materials cure - disposal of contaminated equipment is expensive. Vacuum or wet-mop any dust from grinding or cutting operations - do not dry sweep. Inspect playground area for any hazards including protruding fixings, sharp edges, or trip hazards requiring attention before handover. Prepare handover documentation including installation date, materials used with batch numbers and supplier certifications, installed depths or thicknesses at measured locations, photos of completed installation, impact testing results, and maintenance recommendations. Provide client with material-specific maintenance requirements including inspection frequency, topping-up requirements for loose-fill materials, and expected lifespan. Prepare site-specific safety signage if required showing maximum fall heights for different playground areas.

Safety considerations

Wear appropriate PPE during cleanup including gloves when handling contaminated materials or chemical residues. Use proper waste segregation separating recyclable materials from general waste and chemical waste. Ensure chemical waste is labelled correctly identifying contents before disposal. Clean tools and equipment thoroughly preventing chemical residue transfer to subsequent projects. Properly store or dispose of any remaining materials following manufacturer recommendations. Complete incident reports for any near-misses or safety concerns that arose during project for continuous improvement purposes.

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Frequently asked questions

What are the critical fall height requirements for soft-fall surfacing under AS 4685?

AS 4685 requires playground surfacing to meet impact attenuation performance criteria based on the Critical Fall Height (CFH) of play equipment. The CFH is the maximum height from which a child could fall onto the surface. Surfacing must achieve Head Injury Criterion (HIC) values below 1000 and Gmax values below 200g when tested from the relevant fall height. Different materials achieve different CFH ratings at specific installed depths. For example, bark mulch at 300mm depth typically achieves CFH of 2.5-3.0 metres, whilst rubber tiles might achieve CFH of 3 metres at 50mm thickness. It's critical to match surface material and depth/thickness to the maximum fall heights present in the playground. Testing must be conducted by NATA-accredited testers using standardised impact testing equipment specified in AS/NZS 4422. Surfaces that fail testing must be modified by increasing depth, changing material, or reducing equipment fall heights before the playground can be opened for use.

How do installers prevent isocyanate exposure during wet-pour rubber installation?

Isocyanate exposure prevention requires a hierarchy of controls starting with elimination where possible. Some newer rubber systems use lower-isocyanate or isocyanate-free binders, though these remain less common than traditional polyurethane systems. When isocyanate-containing binders must be used, engineering controls include working in well-ventilated outdoor environments rather than enclosed playgrounds surrounded by buildings. Schedule work during cooler periods (morning) when chemical reactivity and vapour generation is reduced. Administrative controls include limiting worker time in exposure zones through work/rest cycles and training workers to recognise symptoms of overexposure including breathing difficulty, chest tightness, or coughing. Personal protective equipment becomes essential, requiring full-face supplied air respirators or powered air purifying respirators - standard cartridge respirators provide inadequate protection for isocyanate exposures. Chemical-resistant suits prevent dermal exposure which also causes sensitisation. Workers must be medically assessed for fitness to wear respirators and trained in proper donning, use, and doffing procedures. Once a worker develops isocyanate sensitisation, they may be unable to work with these materials again even with PPE, making prevention of initial sensitisation critically important.

What maintenance requirements apply to different soft-fall surfacing types?

Maintenance requirements vary significantly between surfacing types. Loose-fill materials including bark mulch and sand require regular inspection (minimum monthly, more frequently in high-use playgrounds) to verify adequate depth is maintained. Material compacts and disperses over time requiring periodic topping-up, typically annually or when depth measurements fall below specified minimums. Rake loose-fill regularly to redistribute material and prevent bare spots. Foreign objects including glass, syringes, and animal waste must be removed daily in public playgrounds. Replace bark mulch every 3-5 years as material degrades losing impact attenuation properties. Rubber tile systems require less maintenance but inspect regularly for tile movement, separation, or damage. Clean tiles periodically to remove dirt and organic matter. Check edge restraints remain secure. Replace damaged tiles promptly. Wet-pour rubber systems require periodic inspection for surface damage including cracks, delamination, or wear. Clean regularly to remove organic matter. Surface may require re-coating every 5-8 years to maintain appearance and performance. All systems require annual impact testing to verify continued compliance with AS 4685 requirements, with testing frequency increased in high-use facilities or after unusual events such as equipment changes or surface damage. Document all inspections and maintenance activities for compliance records and liability protection.

How should contractors coordinate soft-fall installation with playground equipment installation?

Installation sequencing requires careful coordination to protect completed work and enable efficient workflow. Generally, concrete footings for playground equipment are installed first, allowing concrete to fully cure before soft-fall work commences. For loose-fill systems, material can be installed before equipment assembly, though material will require redistribution and topping-up after equipment installation is complete. This approach allows equipment installers to work on prepared surfaces rather than raw ground. For rubber tile systems, it's generally preferable to install equipment first, then install tiles afterward to prevent damage to tiles from equipment installation activities including dropped components or equipment movement. However, this requires equipment installers to work on unprepared base, potentially requiring temporary surfaces. For wet-pour rubber systems, equipment must be installed first as application around equipment bases requires precise work and any traffic on fresh rubber damages the surface before curing is complete. Establish clear communication between equipment installers and surface installers regarding schedules, work sequencing, and protection of completed work. Consider weather impacts - if rain is forecast, delay surface installation until after weather clears to prevent wet conditions damaging installation quality. Document agreed sequencing in pre-start meeting and assign clear responsibility for protection of completed work phases. Factor adequate time in project schedule for sequencing coordination rather than attempting to compress timelines by having trades work simultaneously in same area.

What are the common causes of soft-fall installation failing impact testing?

Failed impact tests typically result from insufficient material depth or thickness, incorrect material selection for fall heights present, poor base preparation, or installation defects. For loose-fill systems, the most common failure cause is insufficient depth - even 50mm less than specified can cause test failure at high fall heights. Material compaction also causes failures particularly if materials are over-compacted during installation or traffic occurs before testing. Contamination of loose-fill with soil, clay, or fine particles reduces impact attenuation. For rubber systems, inadequate thickness is also a primary failure cause. Wet-pour rubber systems can fail due to incorrect mix ratios causing insufficient material properties, inadequate curing before testing, or holidays (thin spots) in application. Poor base preparation can cause failures if bases are too soft, allowing excessive surface deflection during testing. Installation in wet conditions can compromise rubber systems causing adhesion failures or incomplete curing. To prevent test failures, verify material specifications match fall height requirements before ordering, measure installed depths at multiple locations throughout installation rather than only at completion, follow manufacturer mixing instructions precisely for wet-pour systems, ensure adequate curing time before testing, and engage experienced installers familiar with testing requirements. Consider installing slightly greater depth than minimum specifications to provide safety margin. Factor testing failures into project risk management and schedule adequate time for remedial work and re-testing if required. Some contractors conduct pre-testing using portable impact testing equipment before formal NATA testing to identify issues early.

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