Risk prevention in the precast concrete sector: essential PPE for a safe working environment

Risk prevention in the precast concrete sector: essential PPE for a safe working environment

The precast concrete sector is an essential part of the construction industry.

It involves manufacturing, heavy material handling, machinery maintenance and internal transport, which generates a combination of physical, chemical and ergonomic risks that are highly relevant in terms of prevention.

Having adequate and properly certified Personal Protective Equipment (PPE) is key to reducing accidents and ensuring the health of workers.

Main risks in precast plants

According to the National Institute for Occupational Safety and Health (INSST) and the Spanish National Association of Ready-Mix Concrete Manufacturers (ANEFHOP), the most common risks in this type of facility can be grouped into five categories:

1. Risks associated with handling loads and machinery:

  • Crushing by moulds, presses or overhead cranes.
  • Impact from suspended elements or falling prefabricated parts.
  • Entrapment in vibration systems, conveyor belts or hoppers.

2. Chemical risks:

  • Exposure to cement dust and respirable crystalline silica during mixing or demoulding.
  • o Skin or respiratory irritation from additives, release oils or pigments.

3. Physical risks:

  • Prolonged noise from vibrators and mixers (above 85 dB).
  • o Whole-body vibrations for heavy machinery operators.
  • o Extreme temperatures in curing areas or open spaces.

4. Ergonomic risks:

  • Repetitive movements in formwork or manual handling of parts.
  • Lumbar overexertion due to awkward postures and lifting loads.

5. Risks of falls and slips:

  • Wet floors or floors with cement residue.
  • o Elevated platforms without railings or inadequate access.

Selection of recommended PPE

The choice of PPE must be based on a specific risk assessment for each job, complying with Regulation (EU) 2016/425 and the applicable UNE-EN standards.
The most relevant elements are:

Safety footwear
  • Applicable standards: EN ISO 20345:2022 (protection level S3 or higher).
  • Key requirements: steel or composite toe cap, anti-perforation insole, hydrocarbon-resistant sole with high slip resistance (SRC).
  • Recommended conditions: water resistance (WR) and thermal insulation (HI/CI) for cold or curing areas.
  • Suitable models: INDICAR LINEAS ranges due to their mechanical strength, shock absorption and stability on wet surfaces.
Protective clothing
  • Standard: EN ISO 13688:2013 + A1:2021 (general requirements).
  • Characteristics: abrasion-resistant fabrics, with reinforcements on knees and elbows; preferably with dust-repellent treatment and reinforced seams.
  • In wet or splashy environments, it can be complemented with waterproof garments (EN 343).
Protective gloves
  • Standards: EN ISO 21420:2020 (general requirements), EN 388 (mechanical risks) and EN 374 (chemicals).
  • Types:
    o Nitrile or PVC gloves for handling cement, additives and oils.
    o Gloves with reinforced palms and backs for loading or vibration tasks.
Respiratory protection
  • Standards: EN 149:2001+A1:2009.
  • Recommendation: FFP2 or FFP3 masks in areas with cement or silica dust, replaced regularly and fitted correctly to the face.
  • For prolonged demoulding or cleaning tasks, localised ventilation or powered air-purifying respirators (PAPR) are recommended.
Hearing protection
  • Standards: EN 352-1/2/3 depending on type (ear muffs, earplugs or helmet-mounted).
  • In mixing or vibration environments, noise levels typically exceed 85 dB, so mandatory use and staff rotation are required.
Head and eye protection
  • EN 397 helmets, with chin straps if working at height or in loading areas.
  • EN 166 goggles or screens, resistant to particle projections or chemical splashes.

Complementary preventive measures

In addition to the use of PPE, the integration of collective and organisational measures is essential:

  • Specific training in load handling, working with overhead cranes and the safe use of vibrators.
  • Ventilation and localised extraction systems to reduce silica dust (mandatory under RD 665/1997).
    • Preventive maintenance of equipment and control of dust emissions in hoppers and mixers.
  • Signage and order in the plant: pedestrian routes separated from loading areas.
  • Emergency and first aid plan, with personnel trained in rescue and assistance in the event of entrapment.

🔎 PPE inspection and certification

Personal protective equipment must:

  • Be CE certified in accordance with Regulation (EU) 2016/425.
  • Be kept in good condition and inspected before each use.
  • Be replaced immediately in the event of damage or visible impact.
    Those responsible for prevention must record these inspections in the Health and Safety Plan, following the recommendations of the INSST (Technical Guide RD 773/1997).

Preventive culture and technology at the service of safety

Safety in the precast concrete sector depends as much on the quality of PPE as on training, active monitoring and the preventive culture of each company.

The introduction of state-of-the-art footwear, resistant technical clothing and more effective dust detection systems is significantly reducing occupational injuries and illnesses.

Investing in protection not only complies with a standard: it guarantees continuity of work, the health of operators and the excellence of the final product.