A Field Guide to Safe Concrete and Masonry Construction

A construction worker wearing a white hard hat and gray overalls builds a brick wall using a trowel.

Concrete and masonry are at the heart of every construction environment, from high-rise buildings to roads and bridges. But even though concrete is a strong and reliable resource, working with it is anything but risk-free.

Forming, mixing, placing and finishing concrete presents distinct hazards for workers, and understanding these risks is the first step toward mitigating and preventing their unfortunate outcomes.

Common Hazards in Concrete and Masonry Construction

Safety hazards for construction workers include:

Skin, eye and respiratory irritation from cement dust and chemical exposure
Formwork collapses or falling materials
Slips, trips and falls on wet or uneven surfaces
Chemical burns from direct contact with wet concrete
Overexertion injuries from heavy lifting and awkward postures
Noise exposure from machinery and power tools
Confined space dangers in enclosed pouring areas
Impacts or crush injuries from equipment and vehicles
Safety and Concrete Products
Concrete and Masonry Construction Safety Guide

Primary Risks Across the Different Concrete Working Phases

Forming Risks

Creating strong, stable formwork, or forms, to hold the mix in place as it sets after pouring is a crucial initial step of working with concrete. However, the forms themselves can be dangerous if set up incorrectly. Injuries during this stage often result from structural failures or falls. Hazards can include:

Falls during rebar tying or formwork erection
Collapse of poorly braced forms
Falling materials during formwork striking
Silica dust exposure when cutting forms
Manual handling strain from heavy materials
Skin irritation from wet materials or debris
Federal Regulations on Masonry for Injury Prevention
Safety Manual: Concrete Construction

Mixing Risks

Mixing may seem routine, but airborne cement dust and caustic reactions with moisture can create serious health risks, like:

Cement dust exposure from bag dumping, cutting or grinding
Skin contact with wet cement reacting with sweat
Irritated eyes, nose and throat
Progressive lung damage, such as silicosis
Contamination of food and drinks when consumed in dusty areas
Concrete Worker Safety Briefing
Health Hazards From Cement Handling

Placement Risks

Pouring concrete is a physically demanding task with multiple dynamic hazards, many of which increase when surfaces are unstable or wet. These can include:

Slips on surfaces with a slick, wet mixture
Falls from unstable formwork or improperly supported rebar
Pinch points and crush zones near machinery or hoses
Vehicle and equipment strike hazards
Caustic skin burns from wet cement
Uncapped rebar impalement
Job Safety Analysis for Cutting Concrete
Dust Control for Concrete Work

Finishing Risks

Timing and coordination are critical when finishing concrete. At this stage, workers often operate under time pressure and in close proximity to hazardous materials and tools. Dangers in this step can include:

Electrocution risks from long-handle floats near power lines
Silica dust exposure from dry cutting or sweeping
Chemical hazards from curing compounds or sealants
Inhalation risks from compressed air cleaning methods
Extended kneeling or crouching, leading to ergonomic strain
Concrete Pavement Construction Basics
Site Safety Training for NYC Construction
Concrete Finishing In-Depth Guide

How to Work Safely With Concrete

Comprehensive PPE use, good hygiene practices and awareness of surrounding conditions in construction environments are all critical to preventing both catastrophic accidents and cumulative damage to worker health.

Protect Your Head and Eyes

Concrete jobs are full of airborne debris, fast-moving equipment and unsteady footing. Protecting your head and eyes is essential at all times.

Always wear a hard hat on active construction sites.
Use protective eyewear with side shields or goggles rated for dust and impact.
If exposed to cement or debris, flush eyes immediately at an eye wash station.
Never remove eye protection while working with wet concrete or during grinding/cutting tasks.
Eye and Face Protection Manual
Choosing Eye and Face Protection

Protect Your Skin

Concrete and skin don't mix. The chemicals in cement can cause everything from mild irritation to third-degree burns.

Wear long sleeves, full-length pants and alkali-resistant gloves when working with concrete.
Use waterproof boots that extend above the ankle.
Avoid direct contact with wet or dry cement; never kneel or sit on damp concrete.
Wash any exposed skin immediately with clean water and mild soap.
Never allow cement to remain in contact with skin.
Cal/OSHA Pocket Guide for Construction Workers
Cal/OSHA Safety Training for the Construction Industry
Construction Health and Safety Personal Protective Equipment

Protect Your Respiratory System

Silica dust is invisible, deadly and present at nearly every stage of concrete work. Inhaling it can lead to permanent lung damage.

Wear a properly fitted respirator when cutting, grinding or mixing.
Avoid dry sweeping; use wet methods or HEPA vacuums to control dust.
Never eat, drink or smoke in dusty areas.
Schedule regular air monitoring to assess dust levels on site.
Stay upwind of cutting or mixing operations whenever possible.
Control of Crystalline Silica Dust
Respirable Crystalline Silica Standard for Construction