Working safely with plasterboard

Plasterboard hazards and risks

A hazard is something that can cause harm. A risk is the likelihood of harm from a hazard. Harm includes injury, illness and death. Employees who install plasterboard can face a variety of hazards and risks at work. Hazards range from plant and equipment to hazardous manual handling and slips, trips and falls. Risks range from minor hand injuries to being crushed by stored plasterboard.

The risks from working with plasterboard include injuries known as musculoskeletal disorders, or MSDs. Hazardous manual handling causes MSDs or helps cause them. 

Other common risks to employees who install plasterboard include:

• injuries from falls, mainly from heights less than 2 m
• crushing or impact from plant such as elevated work platforms
• crushing from stored plasterboard sheets that fall
• injuries from overturning trolleys loaded with plasterboard sheets
• respiratory conditions caused by plaster dust.

Workplace safety laws

There are laws to keep people safe in the workplace. One of those laws is the Occupational Health and Safety Act 2004. It's known as the OHS Act. The OHS Act helps protect work health and safety in Victoria. It gives employers and other people duties to control risks to health and safety at work. The definition of health under the OHS Act includes psychological health.

The Occupational Health and Safety Regulations 2017 are another set of laws. Known as the OHS Regulations, they build on the OHS Act. They set out how to fulfil duties, obligations and processes that support the OHS Act. Parts of the OHS Regulations that apply to working with plasterboard include:

• Part 3.1, which deals with hazardous manual handling
• Part 3.5, which deals with plant, including powered mobile plant
• Part 4.1, which deals with hazardous substances
• Part 5.1, which deals with construction, including high-risk construction work.

As an employer, you have duties under the OHS Act and OHS Regulations. Your duties include a duty to secure the health, safety and welfare of employees and other people at work. You must do this 'so far as is reasonably practicable'. To fulfil this duty, you must eliminate risks so far as is reasonably practicable. If you can’t eliminate risks, then you must reduce them so far as is reasonably practicable.

To control risks you should follow the hierarchy of control. The hierarchy of control is a step-by-step approach to eliminating or reducing risks in the workplace. It ranks risk controls from the highest level of protection and reliability through to the lowest and least reliable. The OHS Regulations include a hierarchy of control for a variety of risks, including:

• hazardous manual handling, regulation 27
• noise, regulation 34
• falls above 2m, regulation 44
• plant, regulation 98
• construction, regulation 325.

Control risks from working with plasterboard

The following guidance provides steps to help you manage risks to employees working with plasterboard. Following these steps may help you create a safer workplace and protect employees from hazards.

Site risk assessment

Before beginning work, assess the hazards and risks at the worksite. After the assessment, ensure risk controls are in place. Be sure to:

• consult with employees and any health and safety representatives (HSRs)
• regularly review risk controls throughout the project
• review controls when introducing new controls
• review controls when changing work processes, plant or equipment.

Always ensure new controls do not introduce new hazards and risks. WorkSafe guidance can help you prepare for the job. The guidance includes case studies about hazardous manual handling in construction.

Safe Work Method Statement

Installing plasterboard in buildings and structures can be high-risk construction work (HRCW). HRCW is construction work that has certain hazards. The hazards include, for example, work where there is a risk of falling more than 2 m and the movement of powered plant, such as elevating work platforms. Both these hazards are common when working with plasterboard.

If your work is HRCW, you must complete a Safe Work Method Statement (SWMS). A SWMS is a document that sets out:

• the HRCW at a workplace
• the hazards and risks caused by the activities
• the measures to be put in place to control the risks.

You must prepare a SWMS before HRCW starts and complete the HRCW in line with the SWMS. The SWMS should be available at the location of the HRCW. This gives employees an opportunity to review the control measures. It also helps ensure the SWMS can be evaluated and revised as necessary.

There is more information about HRCW and SWMS on the WorkSafe website. You'll also find a SWMS template.

Ordering plasterboard from suppliers

You should aim to minimise double handling of materials at all stages of the job, from start to finish. This includes when engaging a supplier to deliver the plasterboard sheets. When ordering, use suppliers who reduce manual handling for delivery, unloading and transfer of loads.

Confirm that plasterboard suppliers meet safety requirements for transporting, delivering and unloading. Safety requirements can include, for example, delivery trucks with:

• mechanical lifting and unloading equipment
• height-adjustable steps
• footrails
• handrails
• adjustable and extendable planks
• trolleys.

Where possible, pre-measure jobs and order plasterboard sheets to fit the space. This will help reduce the cutting and manual handling of sheets.

Site preparation

A well-prepared worksite helps provide a safe and efficient work environment. Consider the following when preparing the worksite:

• Plan ahead to avoid or minimise double handling as much as possible.
• Make sure an appropriate traffic management plan (TMP) is in place and that the TMP is followed.
• Make sure you have obtained the necessary permits or approvals before work starts. This includes approvals from local government, authorities and asset owners. The Energy Safe Victoria website has guidance for work near overhead powerlines.
• Appoint an employee to supervise the delivery of plasterboard. For example, a site supervisor.
• Schedule plant such as tower cranes to be available when required.
• Provide a parking area for the delivery truck as close to the work area as possible. Make sure the delivery vehicle has clear access for delivery and unloading. Also make sure there is access for forklifts, cranes, trolleys and other plant.
• Make sure the ground or floor is suitable to transport plasterboard. This includes from the delivery vehicle to the final destination inside the site.
• Make sure visibility is good. Provide extra lighting if necessary.
• Make sure the area for unloading is safe and clear of hazards. Cover trenches and holes with appropriate covers.
• Make sure access routes between the delivery site and the work area are clear of hazards. This includes tools and equipment and other workers. Do not remove scaffolding or void protection.
• Make sure the work areas are clean, clear of hazards and well-lit.
• Set aside a temporary storage area for plasterboard, if necessary. Make sure the storage area is as close to the work area as practicable and clear of hazards.

Taking delivery and unloading plasterboard

Taking delivery of plasterboard presents hazards for employees. They can be at risk of MSD and other injuries when unloading plasterboard. Employees can also be at risk when moving the plasterboard to storage or work areas. Always aim to use plant and mechanical aids to move plasterboard. Examples include cranes, lifts, forklifts, trolleys and sheet panel lifters. Plant and mechanical aids will help control MSD risks.

Control MSD risks

As an employer, you have duties under the OHS Regulations. They includes duties to, so far as reasonably practicable:

• identify any hazardous manual handling by an employee.
• eliminate any risk of MSD associated with hazardous manual handling.

If it is not reasonably practicable to eliminate the risk of MSD, you must reduce the risk. You must reduce the risk so far as is reasonably practicable by:

• altering the workplace layout, environment or systems of work that involve hazardous manual handling
• changing the things used in hazardous manual handling
• using mechanical aids
• combining any of these risk control measures.

A risk might remain after using these measures so far as is reasonably practicable. In this case, you must reduce the risk by using information, instruction or training. Again, you must reduce the risk so far as reasonably practicable.

Information, instruction or training can help control the risk of MSD. But you must not rely on them as the only or primary control measures unless none of the listed controls are reasonably practicable.

You’ll find a hierarchy of control for hazardous manual handling in Part 3.1 of the OHS Regulations.

Risks from plant and vehicles

Vehicles and mobile plant are hazards that create risks during plasterboard deliveries. Your TMP should address risks from mobile plant and vehicles during delivery and unloading.

WorkSafe has guidance on construction site traffic management. Part 3.5 of the OHS Regulations also has a hierarchy of control for risks from plant.

Unloading from delivery trucks

Make sure the delivery truck parks as close to the work area as practicable. This will minimise the distance for transporting plasterboard.

Ideally, the delivery truck will have lifting equipment to unload plasterboard. For example, an extendable fork head. In this case, use the lifting equipment to lift and lower plasterboard sheets from the truck.

If manual handling is necessary

Not all delivery trucks have lifting equipment. In this case, your employees might have to manually unload the plasterboard sheets. Manual handling is not the preferred way to unload plasterboard. It creates risks of MSDs. Always aim to use plant and mechanical aids.

Employees should work in teams of at least 2 when manually unloading plasterboard. It is essential to physically match employees whenever team handling is used. Consider their height and physical strength. The team members should have similar lifting capabilities. Carefully plan and coordinate the lift.

Teams should use safe lifting techniques to unload plasterboard from delivery trucks. They should lower sheets to the ground one board at a time. WorkSafe has guidance to help control risks to employees moving or lifting objects. The guidance includes a hazardous manual handling compliance code. WorkSafe also has case studies about hazardous manual handling of construction materials.

Working in teams

When employees work in teams, make sure that:

• one person is appointed to plan and take charge of the operation
• team members have been trained in team lifting
• there are enough people in the team to handle the weight of the load and the difficulty of the lift
• ground or surface conditions are assessed before the lift
• team members know their responsibilities during the lift
• team members rehearse the lift
• the weight of loads is kept to a minimum
• team members do not exceed their abilities
• enough space is available for the team to move as a group
• the team uses aids to help with handling where possible
• training is provided in the use of lifting aids.

Moving plasterboard sheets at the worksite

Use cranes, forklifts and other suitable plant

Using a crane, forklift or other suitable plant is the best way to move plasterboard sheets at the worksite. Using appropriate plant can help control risks, including the risk of MSD. For example, a crane with a plasterboard lifter can lift multiple sheets of plasterboard to the worksite in a multi-storey building. Manual handling by employees is minimal.

In contrast, manually carrying plasterboard sheets requires manual handling. At least 2 people have to carry sheets up multiple flights of stairs, multiple times. This process is physically demanding. It increases the risk of injury and damage to the materials.

Although plant can help you control risks, it can create others. You must control the risks from plant, so far as is reasonably practicable. WorkSafe has guidance about controlling risks from plant. The guidance includes a plant compliance code.

Using a plasterboard trolley

Plant such as cranes or forklifts might not be available. In this case, employees should use an appropriate mechanical aid. A plasterboard trolley is an appropriate mechanical aid to move plasterboard. The following guidance may help control risks when using plasterboard trolleys to move plasterboard:

• Use an appropriate trolley designed and manufactured to carry plasterboard sheets. Make sure the trolley is designed so it will not topple when loaded.
• Trolleys operate best on smooth hard surfaces. They can overturn if floor or ground surfaces are not suitable. Assess the ground or surface conditions and confirm they are suitable for the trolley.
• A team of at least 2 employees should load the trolley, using safe lifting techniques.
• Make sure loads are within the trolley's capacity.
• Secure the plasterboard sheets to the trolley.
• A team of 2 employees should move the trolley to the storage or work area. One team member should control the trolley from the front. The other should be at the rear, helping guide the trolley.
• A team of at least 2 employees should unload the trolley.

If employees have to carry plasterboard

Using a mechanical aid or plant might not be reasonably practicable. In this case, employees might have to manually carry plasterboard. Make sure double handling is minimised where possible.

To manually carry a plasterboard sheet, employees should follow these steps:

• Work in teams of at least 2.
• Never lift or carry more than one sheet at a time.
• Make sure the route is clear and has space for the team to manoeuvre.
• Communicate and plan the lift.
• Stand facing the plasterboard, a similar distance from each end of the sheet. This will help ensure team members equally share the weight. If the board is long or conditions are windy, place another employee in the centre of the sheet.
• Tilt the sheet so it is almost vertical. The sheet should be close to the body.
• Together, hold the plasterboard with both hands and lift. Use the legs, not the back, when lifting.
• Drop the carrying hand to the bottom of the sheet to support it from the bottom edge.
• Face in the direction of travel and rest the sheet against a shoulder. Use the free hand to support and steady the load.
• Minimise changes in board orientation when handling. For example, avoid rotating sheets or moving them from vertical to horizontal.
• Keep carrying distance to a minimum. Make sure employees do not exceed their abilities.

Avoid stairs

Avoid the need to carry plasterboard up or down stairs. Manually handling sheets on stairs forces employees to use awkward postures. It has a high risk of MSD. Employees are also at risk of falling. Where practicable, create and use access routes that avoid stairs. For example, through external openings or floor openings.

Remember, manual handling is not the preferred way to move plasterboard. Always aim to use plant or mechanical aids such as trolleys.

Storing plasterboard

Store plasterboard sheets as close as practicable to where the work is taking place. This will help reduce manual handling.

Store plasterboard in a way that prevents the collapse of sheets. As far as is possible, store sheets horizontally. Where possible, store sheets off the ground above knee height. Storing plasterboard above knee height reduces manual handling. It also improves access for lifting equipment.

Plasterboard sheets are heavy. The weight of stored sheets may exceed floor loading limits, especially on suspended slabs. Consider the following:

• Weight distribution. Concentrate plasterboard storage in areas with adequate load-bearing capacity.
• Load limits. Adhere to the specified floor loading limits.
• Cumulative effect. The combined weight of multiple stacks can exceed floor capacity even if individual stacks are within limits.

Vertical storage

The amount of available space can make it difficult to store sheets horizontally. You may need to store sheets vertically. In this case, keep vertical storage to a minimum. Vertical stacks create a tipping and crushing hazard.

If storing plasterboard sheets vertically:

• Always stack them on their long side.
• Ensure the stack cannot collapse. Consider using a frame system with ratchet ties to hold vertically stacked sheets flush.
• If stacking against a wall, limit vertical stacks to 6 sheets. Fix stacks securely to the structure.

It's crucial to consider lateral loading when storing plasterboard sheets vertically. Lateral loading is the application of horizontal forces a structure. Vertically stored plasterboard can exert significant lateral loading on frames or walls. The force from lateral loading can affect wall stability and frame integrity.

Measuring and cutting plasterboard

Measuring and cutting plasterboard sheets can place employees at risk of MSD. Employees might twist, bend, crouch and kneel as they measure and cut. They might also adopt awkward postures when gripping and using tools. Employees can also be at risk from cuts and plaster dust when cutting the plasterboard.

The following actions may help control risks from measuring and cutting plasterboard:

• Use score and snap cutting techniques.
• Measure and, if possible, cut the plasterboard when it is horizontal and flat.
• Reduce cuts to vertical boards as much as possible. Reducing cuts to vertical boards reduces the need to squat or kneel to measure or cut. This helps avoid bending and twisting and strain on lower limbs.
• When cutting plasterboard, cut away from the body. Avoid pulling knives towards the body.

Wear appropriate personal protective equipment (PPE). For example, safety glasses, safety footwear, dust masks and cut-resistant gloves. Safety data sheets may include information about PPE requirements.

Installing plasterboard

Hazards when installing plasterboard

Installing plasterboard can be hazardous and place employees at risk. Hazards include the following:

• The size and weight of plasterboard sheets. For example, fire-check sheets are thicker and heavier than standard plasterboard sheets. They can be awkward to handle.
• Lifting and carrying plasterboard.
• Lifting a plasterboard sheet above head height.
• The frequency of lifts.
• Static and awkward postures. For example, kneeling, squatting, bending, twisting and reaching.
• Using the head or neck to support the weight of the sheet when fastening.
• Working below knee height and above shoulder height. This includes standing with both hands above the head to hold ceiling plasterboard in place.
• Looking up while installing plasterboard, causing hyperextension of the neck.
• Using tools such as drills and screw guns. Working in awkward postures increases the risk when using tools.
• Falls, including falls from below and above 2 m.
• Plaster dust.

Controlling risks when installing plasterboard

The following guidance may help control risks to employees who install plasterboard:

• Work in teams of 2 or more. The size and weight of plasterboard sheets will help determine the number of employees in a team.
• Use mechanical aids to lift and hold plasterboard in place. For example, adjustable failsafe sheet lifters and props. Follow the manufacturer's instructions when using mechanical aids.
• Make sure employees use a sheet lifter:
  • for all overhead work
  • to install sheets weighing more than 28 kg
  • to install sheets where safe access is limited.
• Identify the number of sheets required in the work area.
• Confirm the dimensions and weight of the sheets.
• Confirm there are sufficient team members in relation to the size and weight of the sheets.
• Store sheets as close as practicable to where they will be fixed.
• Stack sheets in an alignment that matches how they will be installed. If sheets need to be moved, use mechanical aids such as a trolley. If using aids is not practicable, follow the instructions for manually moving plasterboard.
• Wear appropriate PPE. For example, safety glasses, safety footwear, dust masks and gloves.
• Use lightweight and low-vibration screw guns and drills. Cordless tools will help reduce trip hazards. Ensure tools are regularly maintained and in good working condition.
• If working above ground, use appropriate ladders, steps and platforms. A trestle scaffold is quick and easy to erect. It can be configured into a platform for plastering work. Where practicable, platforms should have fall prevention. Make sure employees are working the correct distance below the installation surface. Take into account the height of the individual doing the work. See WorkSafe's falls prevention guidance for more information. The guidance includes the compliance code, Prevention of falls in general construction.
• Regularly rotate roles. For example, switch between measuring and cutting plasterboard and installing plasterboard.
• Make sure you have a documented system of work. Confirm that the system provides enough information to control risks from work with plasterboard. Consult with employees and HSRs when creating the system of work. Also make sure the induction of employees includes induction to the system of work.

Sanding plasterboard

Employees who sand plasterboard can face a range of hazards. They include plaster dust, hazardous manual handling and noise.

Plaster dust

Sanding plasterboard creates dust that contains calcium sulphate. Employees who sand plasterboard can be exposed to high levels of the dust. People nearby can also be exposed. The dust may present a health risk to employees doing the work and to others nearby. It might also make pre-existing conditions worse, such as asthma and hay fever.

There are legal limits on the safe amount of substances in the air. The limits are called exposure standards. The 8-hour exposure standard for calcium sulphate is 10mg/m3. This means the average amount of plaster dust in the air must not exceed 10 milligrams per cubic metre in any 8-hour period. You can carry out atmospheric monitoring if you need to measure workplace exposure. Monitoring should be done by a person with the required skills, knowledge and experience.

Consult the plasterboard safety data sheet for health and safety information.

The following controls may help you control risks from plaster dust:

• Use sanding tools that create the least dust.
• Use power tools and mixing buckets with M Class or higher on-tool dust extraction and filtration.
• Make sure working areas are well-ventilated with either natural or mechanical ventilation.
• Regularly clean and maintain power tools. Avoid cleaning with compressed air.
• Limit the number of people in areas where sanding is taking place.
• Make sure employees wear PPE. This includes respiratory protective equipment, coveralls and eye protection. Safety data sheets provide information about PPE requirements.

Hazardous manual handling

Sanding plasterboard can put employees at risk of MSDs. This is because sanding can involve hazardous manual handling. Hazardous manual handling can occur through, for example:

• ongoing use of force
• ongoing use of awkward postures
• repetitive movements
• ongoing exposure to vibrations
• loads that are unstable, unbalanced or hard to hold.

The following controls may help control the risk of MSD from sanding plasterboard:

• Make sure hand tools are designed and selected to:
  • be held in a neutral wrist or handshake position
  • allow the hand to retain a comfortable grip span
  • be light and well-balanced, with the heaviest part of the tool behind the wrist
  • be suitable for use by either hand
  • provide a good grip surface
  • prevent an employee from adopting a pinch grip with high force or for long periods.
• Minimise the level of muscular effort needed to use hand tools by:
  • using power tools where possible
  • suspending or supporting heavy tools where they are used repetitively and in the same place
  • counterbalancing heavy tools that are used repetitively and need to be kept away from the body
  • using trigger locks where the grip has to be sustained for more than 30 seconds
  • selecting tools that produce the least amount of vibration
  • reducing impact shocks
  • limiting torque or 'kick back’ reactions
  • providing adequate recovery times following long use.
• Provide appropriate platforms for employees to work from. This may reduce the need to bend or reach or use awkward postures.
• Make sure employees have regular breaks from sanding work.
• Maintain tools and equipment. Carry out regular inspections and service in line with manufacturer directions.

You can find information about hazardous manual handling on the WorkSafe website. Part 3.1 of the OHS Regulations has a hierarchy of control for hazardous manual handling.

Noise

Powered sanding machinery can be noisy. Excessive noise may cause hearing loss. As an employer, you have a duty to ensure employees are not exposed to excessive noise.

The OHS Regulations set out a noise exposure standard. You must ensure employees' exposure to noise does not exceed the exposure standard. The noise exposure standard in decibels is:

• an 8-hour average of 85 dB(A) at an employee's ear level
• a peak noise level of 140 dB(C) at an employee's ear level.

Employees’ exposure to noise depends on the level of exposure and the duration of that exposure. If you have to shout to communicate with people nearby, your exposure may exceed the standard.

Part 3.2 of the OHS Regulations includes a hierarchy of control for exposure to noise.

You must eliminate the source of the noise so far as is reasonably practicable. If you can't eliminate the source of the noise, you must reduce the noise so far as is reasonably practicable. You must do this in line with the following hierarchy of control:

• substitute noisy plant or processes with quieter plant or processes, or
• use engineering controls, or
• use a combination of the previous 2 control measures
• use administrative controls
• provide hearing protection.

You must apply each level of the hierarchy before moving down to the next control measure. You must do this so far as is reasonably practicable. This means you cannot go straight to hearing protection to control the noise. You must first apply the higher-level controls, so far as reasonably practicable.

WorkSafe has guidance that can help control risks from noise. The guidance includes a compliance code for noise.