Sprayed Fireproofing Application SWMS

Sprayed fireproofing application involves the pneumatic spraying of cementitious or fibrous fire-resistive materials (typically vermiculite-based or mineral fibre) onto structural steel, decking and services to achieve rated fire protection. Work is performed at height from scissor lifts, boom lifts or scaffold, frequently inside partially enclosed plant rooms, riser shafts, lift motor rooms and service voids that meet the definition of a confined space. Operators are exposed to airborne mineral fibres, respirable crystalline silica from cementitious binders, alkaline overspray, high-pressure hose whip, powered mobile plant movement and slip hazards from wet rebound. Older buildings may also present in-situ asbestos-containing fireproofing that must be identified before disturbance.

Under the Work Health and Safety Regulation 2025 (NSW), sprayed fireproofing triggers high risk construction work under section 291 — specifically risk of fall greater than 2 metres (291(a)), work in or near a confined space (291(f)), and work involving movement of powered mobile plant (291(o)). Section 299 requires a Safe Work Method Statement to be prepared before work commences, addressing hazards, controls and their implementation. Controls follow the hierarchy under section 36 of the Regulation, prioritising elimination and engineered controls over administrative measures and PPE.

Hazards identified

12 hazards covered, sorted by priority.

Control measures

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

1. 1Eliminate work at height where practicable by pre-spraying steelwork at ground level or in fabrication yard prior to erection; where not practicable, use EWPs selected and operated per AS 2550.10 with harness and lanyard anchored to the manufacturer-designated point.
2. 2Substitute high-silica cementitious products with low-silica mineral fibre or vermiculite formulations where the fire rating specification permits; obtain SDS confirmation of crystalline silica content <1%.
3. 3Prior to any work in buildings pre-2004, review the asbestos register (WHS Regulation 2025 section 425) and conduct pre-work sampling of existing fireproofing; do not disturb suspect material until cleared or removed by a licensed Class A removalist under section 485.
4. 4For confined space entry, apply AS/NZS 2865 — issue a confined space entry permit, conduct pre-entry atmospheric testing (O₂, LEL, dust), provide continuous mechanical ventilation and forced-air extraction, and maintain a trained standby person with rescue equipment.
5. 5Engineer traffic management to separate powered mobile plant from workers on foot: exclusion zones, spotters, plant-pedestrian barriers and reversing alarms per AS 2550.1; only ticketed operators with HRW licence (WP for booms >11 m) may operate EWPs.
6. 6Control airborne dust with on-tool water suppression at the spray nozzle, LEV extraction in enclosed areas, and wet clean-up methods; comply with the workplace exposure standard of 0.05 mg/m³ (8-hr TWA) for respirable crystalline silica.
7. 7Provide respiratory protection selected per AS/NZS 1715 and AS/NZS 1716 — minimum P2 for low-dust tasks, powered air-purifying respirator (PAPR) with P3 filter for spraying and confined space work; conduct fit-testing per AS/NZS 1715 Appendix E.
8. 8Implement health monitoring for workers exposed to crystalline silica and SMF per WHS Regulation 2025 sections 368–378, including baseline and periodic chest imaging and respiratory function testing.
9. 9Inspect hoses, couplings and whip-checks before each shift; fit hose restraints at all connections; establish blockage-clearing procedure including depressurising the line, locking out the pump and standing clear of the nozzle end.
10. 10Provide chemical-resistant PPE per AS/NZS 2210 (safety footwear), AS/NZS 1337 (eye protection — sealed goggles for spraying), nitrile or PVC gauntlets, and disposable Type 5/6 coveralls; hearing protection to AS/NZS 1270 where sound levels exceed 85 dB(A).
11. 11Isolate and de-energise electrical services within the spray zone under a permit-to-work; verify dead with a tested test-lamp before spraying near switchboards, cable trays or luminaires.
12. 12All workers to hold CPCCWHS1001 (White Card); the SWMS is to be developed in consultation with workers per section 47 of the WHS Act 2011 (NSW), signed on before commencement, and reviewed under section 302 of the WHS Regulation 2025 whenever controls change, an incident occurs or a worker raises a concern.

Applicable Codes of Practice

High-Risk Construction Work triggered

Worked example

A passive fire protection subcontractor is engaged to apply sprayed vermiculite fireproofing to 2,400 m² of structural steel across three levels of a new commercial building in Parramatta. The steel beams sit 4.2 m above the working slab, and a portion of the scope is inside two mechanical plant rooms accessed via a single doorway — a confined space under AS/NZS 2865. The crew works from two 19 ft electric scissor lifts while a telehandler shuttles bagged product. Before mobilisation, the subcontractor prepares this SWMS, verifies operator HRW licences and White Cards, and consults the crew under section 47. Pre-entry atmospheric testing and forced ventilation are established for the plant rooms, and PAPR respirators with P3 filters are issued. Mid-project, an HSR raises a concern about visible rebound accumulating on the scissor lift platform, triggering a section 302 review — the SWMS is revised to require mid-shift platform cleaning and additional non-slip matting before work resumes.

Related legislation

• Work Health and Safety Act 2011 (NSW) — sections 19, 31, 32, 47
• Work Health and Safety Regulation 2025 (NSW) — sections 36, 291, 299, 302
• Work Health and Safety Regulation 2025 (NSW) — Part 4.3 Confined Spaces (sections 62–77)
• Work Health and Safety Regulation 2025 (NSW) — Part 4.4 Falls (sections 78–80)
• Work Health and Safety Regulation 2025 (NSW) — Part 8 Asbestos (sections 419–529)
• Work Health and Safety Regulation 2025 (NSW) — Chapter 7 Hazardous Chemicals (silica health monitoring, sections 368–378)

Frequently asked questions