Expansion Joint Installation SWMS

Expansion joint installation in carparks, bridge decks and trafficable slabs involves cutting out existing joint material, preparing substrates, mixing two-part epoxies or polysulfide sealants, and bedding metal joint profiles or compression seals into the prepared chase. The work routinely exposes installers to silica dust from saw-cutting, isocyanate and amine sensitisers in epoxy components, manual handling injuries from lifting heavy joint profiles, and traffic risk where joints are installed in live or partially live carparks and bridge structures. Under WHS Regulation 2011 r291 this work is classified as High Risk Construction Work because it is performed on or adjacent to a road or railway used by traffic other than pedestrians, frequently involves work at heights on bridges, and uses hazardous chemical products. A Safe Work Method Statement must be prepared, consulted on with workers, and held on site before work commences, and must be reviewed if controls fail or scope changes. This SWMS template covers epoxy nosing joints, metal extruded joints and compression seals across carpark and bridge applications nationally.

Hazards identified

7 hazards covered, sorted by priority.

Control measures

Hierarchy-of-controls order: elimination → substitution → isolation → engineering → administrative → PPE.

1. 1Elimination — Schedule joint installation during full carpark or bridge lane closures so all vehicle traffic is removed from the work zone for the full installation and cure window.
2. 2Elimination — Specify pre-formed factory-cured joint cartridges where design permits, removing on-site epoxy mixing and exotherm exposure entirely from the work sequence.
3. 3Substitution — Select low-VOC, MDI-free epoxy systems with amine-adduct hardeners rated below 0.1% free isocyanate per the safety data sheet to reduce sensitisation potential.
4. 4Substitution — Replace dry abrasive cutting with wet-cut diamond blade systems using continuous water suppression to keep respirable silica below the workplace exposure standard.
5. 5Engineering — Fit on-tool H-class HEPA dust extraction to all saws and grinders, integrated with shadow vacuuming and tested for capture velocity at task commencement.
6. 6Engineering — Install Type 2 longitudinal traffic barriers, water-filled barriers or concrete F-shape barriers between the work zone and any live trafficked lane per AS 1742.3.
7. 7Administrative — Conduct pre-start brief using this SWMS, sign on all workers, rotate saw operators every 60 minutes to limit vibration exposure, and lock out adjoining bays.
8. 8Administrative — Implement a permit-to-work system for hot work and confined chase entry, with spotters in high-visibility garments controlling any residual vehicle movements.
9. 9PPE — P2 half-face respirator fit-tested per AS/NZS 1715, chemical-resistant nitrile gauntlets, Type 5/6 coveralls, safety glasses to AS/NZS 1337 and Class D/N hi-vis to AS/NZS 4602.1.
10. 10PPE — Anti-vibration gloves rated to ISO 10819, hearing protection class 5 for saw cutting, and steel-midsole safety boots to AS/NZS 2210.3 for puncture protection.

Applicable Codes of Practice

High-Risk Construction Work triggered

Worked example

On a four-level suburban shopping centre carpark refurbishment, a two-person joint crew arrives at 6am to replace 42 lineal metres of failed epoxy nosing joint across Level 2. The supervisor opens this SWMS on a site tablet at the pre-start brief, walks both installers through the seven listed hazards, and confirms today's specific controls: the centre management has closed the eastern half of Level 2 to vehicles, water-filled barriers are positioned along the live lane, and the wet-cut saw is paired with an H-class vacuum. Both workers sign on against the control list, confirming P2 respirators are fit-tested and SDS for the selected epoxy is in the site folder. Mid-task, the installer notices the dust extraction capture is reduced because the chase has filled with slurry — they stop work, refer back to the engineering control on this SWMS requiring verified capture velocity, clear the chase with the wet vac, and resume only once suction is restored. At 11am a delivery vehicle is mistakenly directed into the closed bay; the spotter halts work under the administrative control clause, the supervisor radios centre management to reinstate the closure, and the SWMS is annotated with the near-miss before re-signing on. The completed signed SWMS is retained for the project record and uploaded to the principal contractor's HSE system that evening.

Related legislation

• WHS Act 2011 (model)
• WHS Regulation 2025
• AS 3958 — Ceramic tiles; AS 4654 — Waterproofing membranes