In brief
Starter bars projecting from columns, walls and foundations cause serious impalement injuries to anyone who falls on or strikes them; the Regulation on OHS in Construction Work requires sharp materials that cannot be removed to be protected or covered against impalement. Small plastic mushroom caps mostly protect against bumps and scrapes; where there is a fall risk, the fall is prevented first, and the bar is bent over or covered with a load-rated cover. In rebar preparation the guards on cutting and bending machines stand out, in fixing the load on hands and back, and in moving rebar slings and load balance.
Why are starter bars so dangerous?
At almost every stage of the structural frame, starter bars project from somewhere: column starters rising from the foundation, wall reinforcement waiting for the next floor, lap bars sticking out from a slab edge. The ends of these bars are blunt but narrow; when the body weight of a person falling on them is concentrated on this small area, the bar can penetrate skin and muscle. Rebar impalement accidents mostly happen in two ways: falling onto starter bars from formwork, scaffolding or ladders, and walking or bending into a bar at eye, face or abdomen height.
The legislation defines this risk clearly. In the section of Annex 4 of the Regulation on Occupational Health and Safety in Construction Work on general minimum requirements for workplaces on construction sites, materials and waste with sharp points or edges are to be removed from work areas regularly; those that cannot be removed are to be protected or covered with protective materials against the risk of impalement. A starter bar is a typical example of a sharp material that cannot be removed. For the general structure of the regulation, see our article on the Regulation on OHS in Construction Work.
When is a rebar protective cap enough?
The most common measure on sites is a plastic mushroom cap fitted on the end of the bar. These caps are useful, but they do not cover every situation. Most of the small mushroom caps on the market are designed to protect a person who bumps into or brushes against a bar from cuts and scrapes; they are not strong enough to bear the weight of a person falling from height and prevent impalement. The choice of rebar protective cap should therefore be based on the kind of work done below and around the bars:
| Situation | Main risk | Recommended protection |
|---|---|---|
| Bars at ground level, outside walkways | Bumps, scrapes, tripping and falling | Mushroom cap, and separating the walkway from the bars |
| Bars on walkways and material carrying routes | Bumps, impalement when falling | A load-rated profile or timber box covering the whole row of bars, rerouting the walkway |
| Horizontal bars at eye and face height | Eye and face injuries | A brightly coloured cap on the end, taping off the area |
| Bars below formwork, scaffolding or a slab edge | Impalement from a fall from height | Prevent the fall first (edge protection, scaffold guardrails); bend the bar over or cover it with a load-rated cover |
| Short pieces of rebar cut off and left behind | Impalement, tripping | Collect immediately, a separate container for offcuts |
Where there is a fall risk, the first priority is to prevent the person from falling. For slab edges and openings, see our article on floor openings and edge protection. If bars are to be bent over and later straightened for concreting or a new floor, the site manager must confirm that this complies with the reinforcement design.
Rebar preparation: cutting and bending machines
The rebar preparation area on site is a small workshop, and workshop rules apply here too. For steel fixer safety, the following points stand out on cutting and bending machines:
- Guards: The moving parts of the cutting blade and bending disc are not left unguarded. Crushing of hands and fingers between the bending pins is the most common injury; the machine does not run while a bar is being placed on the pins.
- Pedal: The foot pedal should be covered on top; the pedal must not start the machine if material falls on it or it is pressed inadvertently.
- Emergency stop: It must be within easy reach of the operator and in working order. For details, see our article on the emergency stop button.
- Short pieces: When cutting very short pieces, the piece may be ejected; nobody stands in front of the machine, and eye protection is used.
- Electricity: Annex 4 of the Construction Work Regulation requires body earthing of electrically powered work equipment on site and the use of residual current devices in main and sub-distribution boards. Cables are not run unprotected under rebar stacks or across vehicle routes.
- Maintenance: Blade changes and fault interventions are carried out after energy has been isolated and locked out.
The layout of the rebar preparation area also determines accidents. The cutting and bending area is taped off and not set up below the crane path; the floor is kept level, dry and well lit. Separate stacking areas are set for raw rebar, cut pieces and scrap; offcuts are not left on the ground but collected in a separate container. In rainy weather, electric machines are operated in an enclosed or covered area, and cables are kept away from puddles. The area should be planned in step with the floor where formwork and concreting work is concentrated; for the risks of this stage, see our article on formwork and concrete pouring risks.
Our article on machine guards gives guidance on the general principles of machine guarding.
Rebar fixing: load on hands, back and knees
Rebar fixing is done for hours while bending, kneeling and repeating the same hand movement. Tie wire and bar ends cut the hands, constant bending strains the back, and walking on slab mesh carries a risk of tripping and twisting an ankle. Practical measures are:
- Gloves: Cut- and puncture-resistant gloves with a suitable grip surface are used; for selection, see our article on choosing work gloves.
- Footwear: Safety shoes with puncture-resistant soles and toe protection are worn. Our article on safety footwear classes explains the classes.
- Back and knees: Long-handled tying tools or rebar tying machines reduce bending time; knee pads are used for kneeling work, and tasks are rotated.
- Walkways: Temporary walking platforms or planks are laid along the routes where people will walk on slab mesh.
- Heat and sun: In summer, shade, water and breaks are planned for crews working on open slabs.
Moving rebar: by hand and by crane
When moving rebar, the ends of long bars can strike others where the carrier cannot see. When carrying by hand, long bars are carried by two people at shoulder height, the carrying route is separated from areas where people are working, and overhead power lines are not approached. For the general principles of manual handling, see our article on manual handling and lifting technique.
When moving by crane, the following rules apply:
- A rebar bundle is lifted not by its tie wire but with a suitable sling attached at a minimum of two points.
- The balance of the load is checked with a short trial lift before lifting.
- Long loads are guided with a tag line; nobody stands under the load or in its swing area.
- Slings, chains and hooks undergo periodic inspection at least once a year under Annex III of the Work Equipment Regulation and are visually checked before each use. For details, see our article on slings, chains and lifting accessories.
- Rebar bundles are stacked neatly on bearers so that they cannot topple and their ends do not project into walkways.
Vocational training and site supervision
Construction work is on the list in the regulation governing mandatory vocational training in hazardous and very hazardous work; the certificates of those doing rebar work on site need to be checked in this respect. We explained which jobs are covered in our article on the list of occupations requiring vocational training. We plan the 40-hour vocational training modules approved by MEB (the Ministry of National Education) through our solution partners working under Public Education Centre protocols, and select the modules together with the business according to the subject of the work. For details, see our vocational training page.
Link site supervision to a daily checklist: uncapped bars, cutting and bending machines with guards removed, rebar projecting into walkways, unsuitable slings. For a general list, you can use our article on the construction site OHS checklist. We carry out risk assessments and site tours on construction sites as part of our OHS specialist services; for sector-specific topics, see our construction page.
Frequently Asked Questions
Is a rebar protective cap mandatory?
The Regulation on OHS in Construction Work requires sharp materials that cannot be removed to be protected or covered against the risk of impalement. The regulation does not name a specific product; a suitable method of protection is chosen, such as a cap, cover, profile or bending the bar over.
Do plastic mushroom caps protect against falls?
Most small plastic mushroom caps protect against bumps and scrapes; they are not strong enough to prevent impalement of someone falling from height. Where there is a fall risk, the fall is prevented first, and the bar is bent over or covered with a load-rated cover.
What is the most common accident on rebar cutting and bending machines?
Trapping of hands and fingers between the bending pins, and the machine starting when the pedal is pressed inadvertently, are among the most common accidents. A pedal guard, a working emergency stop and the machine being stopped while the piece is placed prevent these accidents.
Can a rebar bundle be lifted by its tie wire?
It should not be. Tie wire is not designed for lifting and can snap. The bundle is lifted with a suitable sling attached at a minimum of two points.
A certified specialist matched to your hazard class: site inspections, approved logbook, training plan, annual plan and report follow-up.
Bursa SİSTEMER OSGB Technical Team — written from the field experience of our OHS specialists and workplace physicians. Legal information is valid as of the publication/update date; contact us for an assessment specific to your business.