Comprehensive safety procedures for brick and block laying including manual handling, scaffold safety, and mortar work

Brick and Block Laying Safe Work Method Statement

Australian WHS compliant SWMS template

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Brick and block laying is one of the most fundamental and enduring construction trades in Australia, forming the structural and aesthetic foundation of residential, commercial, and industrial buildings. This Safe Work Method Statement provides comprehensive safety procedures for bricklaying and block laying operations, addressing the significant hazards inherent in this physically demanding work including manual handling of heavy materials, working at heights on scaffolding, exposure to cement and mortar, silica dust generation during cutting, and use of power tools. Whether constructing single-storey residential brick veneer, multi-storey commercial masonry walls, or structural blockwork foundations, this SWMS ensures compliance with Australian Work Health and Safety legislation while protecting workers from injury and long-term health effects.

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Overview

What this SWMS covers

Brick and block laying is the skilled trade of constructing walls, partitions, and structures using clay bricks, concrete blocks, and mortar binding materials. This work is fundamental to Australian construction, with brick veneer being the most popular external wall cladding for residential buildings and concrete blockwork providing structural and partition walls for commercial and industrial projects. Bricklayers and blocklayers work across new construction, renovation, extension, and repair projects, building everything from single-storey homes to multi-storey commercial buildings. The work involves interpreting architectural and structural plans, setting out wall positions with precision, mixing or preparing mortar to correct consistency, laying bricks or blocks in specified bond patterns while maintaining alignment and level, cutting materials to fit openings and corners, and finishing joints for weatherproofing and aesthetics. Modern bricklaying combines traditional hand skills with contemporary technology including laser levels for alignment, diamond saws for cutting, and mechanical lifting aids for material handling. Brick and block laying presents significant physical demands and safety hazards that must be managed through comprehensive risk controls. Workers handle materials weighing 3-20 kilograms repeatedly throughout each shift, work at various heights on scaffolding and work platforms, operate cutting equipment generating silica dust, handle alkaline cement-based mortars, and work in outdoor environments exposed to weather extremes. The repetitive nature of the work, combined with awkward postures and heavy loads, results in high rates of musculoskeletal injuries affecting the back, shoulders, knees, and wrists. This Safe Work Method Statement addresses all high-risk construction work components of brick and block laying including working at heights above two metres, scaffold access and use, manual handling of heavy materials, exposure to hazardous substances including silica dust and cement, use of powered equipment, and environmental factors such as heat stress and sun exposure. It establishes control measures following the hierarchy of control principle, specifies personal protective equipment requirements, details pre-work and ongoing inspection procedures, and provides step-by-step work procedures ensuring both worker safety and quality outcomes. Compliance with this SWMS is mandatory for all workers, supervisors, and subcontractors engaged in brick and block laying operations. The document must be reviewed with all workers during site induction, signed acknowledgment obtained, and the SWMS kept accessible at the worksite for reference. Any variations to the work method or identification of additional hazards must trigger SWMS review and update before work continues.

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Why this SWMS matters

Brick and block laying safe work practices are critical for protecting workers in one of construction's most physically demanding and hazardous trades. Under Section 19 of the Work Health and Safety Act 2011, persons conducting a business or undertaking (PCBUs) have a primary duty of care to ensure, so far as is reasonably practicable, the health and safety of workers. For brick and block laying, this includes identifying all reasonably foreseeable hazards, assessing associated risks, and implementing control measures to eliminate or minimise those risks. The Work Health and Safety Regulations 2011 classify several aspects of brick and block laying as high-risk construction work requiring specific controls and, in many cases, a Safe Work Method Statement. This includes work carried out on or near scaffolding, work involving the risk of a person falling more than two metres, work on or near brittle or fragile surfaces, and work in an area where there is potential for exposure to respirable crystalline silica. The regulations require that a SWMS be prepared before high-risk construction work commences, must be kept at the workplace, and must be provided to any person who requests it. Musculoskeletal injuries represent the most common health issue in bricklaying, with manual handling accounting for approximately 40% of serious workers' compensation claims in the masonry trade. The repetitive nature of lifting bricks weighing 3-4 kilograms each, hundreds or thousands of times per day, creates cumulative loading on the spine, shoulders, and knees. When workers bend from ground level to pick up bricks or blocks, twist while loaded, or maintain awkward postures while laying materials, injury risk increases dramatically. Safe Work Australia reports that the average time lost from work for serious musculoskeletal injuries in construction exceeds six weeks, with many workers experiencing chronic pain requiring ongoing treatment and some never returning to full duties. Respirable crystalline silica exposure has become a focus of intensive regulatory enforcement following increased awareness of silicosis prevalence in Australian construction workers. Cutting, grinding, and chasing operations on bricks and concrete blocks release fine dust containing crystalline silica, which when inhaled causes irreversible lung scarring. Recent health screening programs have identified silicosis cases in relatively young workers with less than ten years of exposure, highlighting the serious health impact of inadequate dust controls. SafeWork authorities across Australia have issued prohibition notices, undertaken prosecution action, and imposed substantial fines on contractors failing to implement adequate silica dust controls, with penalties exceeding $100,000 for individual breaches and potential for criminal prosecution where serious harm occurs. Working at heights on scaffolding presents catastrophic risk, with falls from height remaining the leading cause of worker fatalities in Australian construction. For bricklayers working on multi-storey buildings, falls can occur from scaffold platforms, while climbing scaffolding, when reaching beyond edge protection, or during scaffold dismantling. A fall from even two metres onto hard surfaces or protruding materials can cause fatal injuries or permanent disability. The financial and legal consequences are severe, with recent prosecutions resulting in fines exceeding $500,000 and custodial sentences for company directors where inadequate fall protection contributed to worker deaths. Chemical burns from wet mortar, concrete, and cement products cause significant injury and long-term dermatological conditions in bricklayers. The highly alkaline nature of these materials (pH 12-13) causes chemical burns when in prolonged contact with skin, with symptoms ranging from mild irritation to severe blistering and deep tissue damage requiring skin grafts. Many workers develop allergic contact dermatitis from chromium compounds in cement, resulting in chronic skin conditions that can end careers. Early intervention through proper PPE, immediate washing of splashes, and prompt medical treatment for skin irritation is essential to prevent progression to severe dermatitis. Implementing comprehensive safe work practices through this SWMS protects workers from these serious hazards while delivering business benefits including reduced workers' compensation premiums, improved productivity through fewer lost-time injuries, enhanced professional reputation with clients and principal contractors, legal protection demonstrating due diligence, and creation of a positive safety culture that attracts and retains skilled workers.

Reinforce licensing, insurance, and regulator expectations for Brick and Block Laying Safe Work Method Statement crews before they mobilise.

Hazard identification

Surface the critical risks tied to this work scope and communicate them to every worker.

Risk register

High

Bricklayers and labourers repeatedly lift, carry, and position bricks weighing 3-4 kg and concrete blocks weighing 10-20 kg throughout each work shift. This repetitive manual handling involves bending to ground level or low positions to collect materials, lifting while rotating the spine, carrying materials to work position, and reaching or stretching to place materials in final position. The cumulative load over a typical workday can exceed 2-3 tonnes of materials handled manually. This creates significant stress on the lumbar spine, shoulder joints, knee joints, and wrist structures. Workers adopting poor posture to reach materials, twisting while loaded, or lifting from ground level without proper technique experience acute and chronic musculoskeletal injuries. The risk is compounded when working on scaffolding with limited space, in confined areas restricting movement, or when fatigued later in the shift. Lower back strain, herniated discs, rotator cuff injuries, and knee cartilage damage are common consequences.

High

Brick and block laying on structures above single-storey height requires workers to access and work from scaffolding, mobile elevated work platforms, or constructed walls. Workers face fall risks when climbing scaffolding frames to access work levels, working near unprotected edges of scaffold platforms, leaning beyond edge protection to lay external faces, stepping between scaffold lifts or between scaffold and structure, and during material handling on elevated platforms. Multi-storey construction may involve work at heights of 10-20 metres or more, where falls result in fatal or catastrophic injuries. The presence of hard surfaces, protruding brickwork, and stored materials below work areas increases injury severity. Scaffold movement or instability, missing guardrails, gaps in platform planking, and slippery surfaces from mortar spills create additional fall hazards. Falls can also occur during access via ladders, when stretching to reach materials stored on scaffold platforms, or if workers bypass edge protection to access difficult areas.

High

Cutting bricks and concrete blocks to fit openings, corners, and architectural features generates fine dust containing respirable crystalline silica. These microscopic particles, when inhaled, penetrate deep into lung tissue causing silicosis, an irreversible lung disease characterised by progressive lung scarring, shortness of breath, and increased susceptibility to tuberculosis and lung cancer. Brick cutting with masonry saws, angle grinding to trim or shape materials, core drilling through blockwork for services, chasing out channels for plumbing or electrical, and cleaning mortar residue with grinders all generate hazardous dust. Dry cutting produces the highest dust concentrations, with airborne silica levels potentially exceeding safe exposure limits by 100 times or more. The fine nature of the dust means it remains airborne for extended periods, affecting not just the worker performing the cutting but others in the surrounding area. Inadequate ventilation in enclosed areas or building interiors compounds the exposure. Long-term health effects are irreversible, with no cure for silicosis once developed.

Medium

Wet mortar, cement, and concrete have high alkalinity (pH 12-13) that causes chemical burns when in contact with skin. Bricklayers handle these materials continuously during mortar mixing, spreading mortar with trowels, catching drips and spills, pointing joints, and cleaning tools and equipment. The chemical burn process often begins as mild irritation or redness that workers may ignore, progressing to painful blistering, cracking, and deep tissue damage requiring medical intervention. Prolonged or repeated exposure causes cement dermatitis, a debilitating condition presenting as red, dry, cracked skin that may weep, blister, or ulcerate. Some workers develop allergic sensitisation to chromium VI compounds present in cement, resulting in chronic allergic contact dermatitis where even minimal exposure triggers severe skin reactions. This allergic sensitisation can be career-ending as affected individuals cannot tolerate any contact with cement products. Splashes to eyes cause severe pain and corneal damage requiring urgent medical treatment. The risk is highest during initial mixing when cement powder can splash, during wet work with mortar, and when cleaning equipment at the end of shifts.

Medium

Bricks and concrete blocks have sharp corners and rough surfaces that cause cuts and lacerations during handling. The risk increases significantly with cut or broken materials where edges are particularly sharp and jagged. Workers experience cuts when retrieving materials from pallets or stacks, handling cut pieces, during demolition or alteration work where broken masonry is encountered, and when cleaning work areas of material offcuts and debris. Hand and finger lacerations are most common, but arms and legs can also be affected when carrying materials against the body or when kneeling on debris. Deep cuts can damage tendons, nerves, and blood vessels, requiring surgical repair and potentially causing permanent impairment. Contamination of wounds with mortar or soil can lead to infection and delayed healing. Sharp reinforcement protruding from blockwork cores presents additional laceration and puncture risk during laying and when working around partially completed work.

High

Brick and block laying requires use of powered equipment including masonry saws with diamond blades, angle grinders for cutting and finishing, diamond core drills for service penetrations, and concrete mixers for mortar preparation. These tools present multiple hazards: rotating blades and grinding discs can cause severe lacerations or amputations if contact occurs; blade or disc breakage can project fragments at high velocity causing penetrating injuries; electric shock from damaged cables, faulty equipment, or contact with water; noise levels exceeding 85 dB(A) requiring hearing protection; and hand-arm vibration syndrome from prolonged use of handheld tools. Angle grinders are particularly hazardous, with kickback potential when blades bind in cuts and guards removed or damaged by operators seeking better access. Masonry saws with water cooling systems create electrical hazards if water contacts electrical components. Entanglement with rotating parts can occur if loose clothing, gloves, or equipment lanyards contact moving components.

Control measures

Deploy layered controls aligned to the hierarchy of hazard management.

Implementation guide

Implement mechanical aids to eliminate or significantly reduce manual handling of heavy bricks, blocks, and mortar. This includes telehandlers or forklifts to place material pallets at working height on scaffold platforms or work areas, brick tongs and grips that allow workers to carry multiple bricks using larger muscle groups rather than finger grip, vacuum lifters for handling large format blocks or multiple units, scissor lifts or material hoists to elevate materials to upper levels, and wheeled mortar tubs to move wet mortar without lifting.

Implementation

1. Assess site access and layout to identify positions for mechanical material delivery 2. Engage plant operators with appropriate licences for telehandler or forklift operation 3. Position material pallets directly onto scaffold platforms at working height to eliminate lifting from ground level 4. Provide brick tongs or grips rated for the weight of materials being handled 5. Train workers in correct use of mechanical aids and require their use 6. Maintain clear access paths for mechanical equipment throughout the site 7. Schedule deliveries to coincide with mechanical plant availability

Eliminate or minimise respirable crystalline silica dust generation through engineered dust control systems. Wet cutting suppresses dust at the source by using water to bind particles and prevent them becoming airborne. On-tool extraction captures dust at the point of generation through integrated vacuum systems with HEPA filtration. These engineering controls are the most effective means of reducing silica exposure and must be implemented wherever cutting, grinding, or drilling of masonry materials occurs.

Implementation

1. Use masonry saws equipped with integrated water delivery systems that continuously flood the cutting area 2. Ensure adequate water supply and flow rate to achieve effective dust suppression throughout cutting 3. Fit angle grinders with dust shrouds connected to Class M or H vacuum extractors with HEPA filtration 4. Verify vacuum extractors achieve minimum air velocity of 20 m/s at the shroud and are properly maintained 5. Inspect water delivery and extraction systems before use each day to confirm operation 6. Isolate cutting areas with barriers to prevent dust migration to adjacent work areas 7. Prohibit dry cutting unless wet methods are genuinely not practicable, with alternative controls mandated

Eliminate fall risk through properly designed, erected, and maintained scaffolding that provides safe working platforms with integral fall prevention. All scaffolding must comply with AS/NZS 1576 standards, be designed by a competent person for the specific loads and configuration required, erected by qualified scaffolders holding High Risk Work licences, and incorporate full edge protection preventing workers from falling off platforms.

Implementation

1. Engage scaffolding company to design scaffold system accounting for masonry work loads (minimum 50 kg/m² plus stored materials) 2. Verify all scaffold erectors hold current High Risk Work Licence for scaffold work 3. Ensure scaffold design includes fully planked platforms with maximum 25mm gaps, handrails at 900-1100mm height, midrails preventing falls, and toeboards preventing materials falling 4. Confirm scaffold inspection by competent person before first use with green tag attached stating safe working load and inspection date 5. Conduct daily pre-start visual inspection for damage, missing components, overloading, or modifications 6. Do not remove any scaffold components or modify the structure without authorisation from scaffold company 7. Report any concerns about scaffold stability, loading, or integrity immediately and cease work until rectified

Position work surfaces and materials at optimal working height to minimise bending and awkward postures. This involves using adjustable mortar boards, brick packs on scaffold platforms, and wheeled trolleys that maintain materials between hip and shoulder height, significantly reducing spinal loading and injury risk.

Implementation

1. Provide adjustable-height mortar boards or platforms that can be raised as the wall height increases 2. Position brick and block packs on scaffold platforms at the working level rather than ground level 3. Use wheeled trolleys for horizontal movement of materials across the site 4. Implement 'golden zone' material positioning with materials between knuckle and shoulder height 5. Prohibit sustained work requiring bending below knee height or reaching above shoulder height 6. Provide kneeling pads and mats for tasks that cannot be performed at standing height 7. Rotate workers between tasks involving different postures throughout the shift

Establish and communicate clear procedures for safe completion of all brick and block laying tasks. This includes documented work methods, pre-start toolbox meetings, task-specific training, and supervision to ensure procedures are followed. Regular communication reinforces safety expectations and allows identification of hazards specific to each worksite.

Implementation

1. Conduct comprehensive site induction covering all SWMS content before workers commence 2. Hold daily pre-start toolbox meetings (10-15 minutes) to discuss day's work, hazards, and controls 3. Document attendance and topics discussed in toolbox meeting register 4. Provide task-specific training for high-risk activities including height work, cutting operations, and manual handling 5. Assign competent supervisor to oversee work and monitor compliance with safe work procedures 6. Implement permit system for high-risk tasks such as cutting, height work, or work in confined areas 7. Review SWMS whenever site conditions change or new hazards are identified

Manage environmental hazards through work scheduling, provision of shade and rest areas, hydration protocols, and sun protection measures. Australian conditions can exceed 40°C in summer months, creating extreme heat stress risk for workers engaged in physically demanding outdoor work.

Implementation

1. Schedule heavy manual handling and physically demanding work during cooler morning and late afternoon periods 2. Implement mandatory rest breaks in shaded areas every 1-2 hours during hot weather (above 30°C) 3. Provide unlimited cool drinking water and require workers to drink 200-250ml every 15-20 minutes 4. Supply portable shade structures or ensure access to naturally shaded rest areas 5. Train workers and supervisors to recognise heat stress symptoms (fatigue, dizziness, nausea, confusion) 6. Implement buddy system for monitoring heat stress symptoms in coworkers 7. Adjust work/rest cycles based on temperature with increased rest periods above 35°C 8. Require use of sun-protective PPE including wide-brimmed hats, long-sleeved shirts, and SPF50+ sunscreen

Provide, maintain, and enforce use of appropriate personal protective equipment as the final layer of protection when hazards cannot be eliminated through higher-order controls. PPE must be selected to address specific hazards, correctly fitted, properly maintained, and replaced when damaged or worn.

Implementation

1. Conduct PPE assessment identifying all required PPE for each task and work area 2. Provide PPE at no cost to workers and ensure adequate supplies are maintained 3. Fit-test respiratory protection to ensure proper seal and adequate protection factor 4. Train workers in correct donning, use, maintenance, and storage of all PPE 5. Implement daily visual inspection of PPE before use with damaged equipment removed from service 6. Replace PPE on a schedule based on manufacturer recommendations and visible wear 7. Enforce PPE use with clear communication that non-compliance will result in removal from site 8. Maintain PPE register documenting issue, training, fit-testing, and replacement

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Personal protective equipment

Requirement: Class 3 hard hat compliant with AS/NZS 1801

When:

Requirement: Steel toe cap safety boots rated for heavy impacts and compression

When:

Requirement: Cut-resistant gloves rated EN388 Level 3 or higher for handling bricks and blocks

When:

Requirement: Nitrile or neoprene gloves resistant to alkaline materials

When:

Requirement: Impact-rated safety glasses with side protection

When:

Requirement: Fitted disposable P2 respirator or reusable P3 half-face respirator with replaceable filters

When:

Requirement: Class D day/night high-visibility garment with reflective tape

When:

Requirement: Long-sleeved shirt and long trousers with UPF 50+ rating, wide-brimmed hat

When:

Requirement: Earplugs or earmuffs rated for noise reduction

When:

Requirement: Padded knee pads or knee-padded work trousers

When:

Step-by-step work procedure

Give supervisors and crews a clear, auditable sequence for the task.

Field ready

Site Assessment and Work Area Preparation

Begin by conducting a comprehensive assessment of the work area to identify all hazards and confirm readiness for brick and block laying. Walk the entire site perimeter and work area looking for trip hazards such as uneven ground, protruding reinforcement, offcuts, cables, and hoses. Identify overhead hazards including scaffolding above, other trades working at heights, suspended loads, and power lines. Assess ground conditions for scaffold stability if scaffolding will be erected or is already in place. Establish exclusion zones beneath any elevated work areas using barrier mesh or solid hoarding to prevent unauthorised access beneath falling object risk zones. Verify availability of services including water supply for mortar mixing and dust suppression, electrical supply for power tools with RCD protection, and waste disposal bins or skips for masonry offcuts and packaging. Confirm clear access paths for delivery of materials and movement of mechanical equipment such as telehandlers. Review architectural and structural drawings to understand wall positions, openings, lintels, and critical dimensions before commencement.

Safety considerations

Do not commence work until all hazards are identified and appropriate controls are in place. Exclusion zones must be clearly marked and enforced to prevent others entering high-risk areas. Confirm emergency exits and assembly points are identified and communicated to all workers. Ensure first aid facilities and eye wash stations are accessible within 30 seconds travel time from work areas.

Scaffold Inspection and Access Verification

Before accessing scaffolding or permitting workers onto elevated platforms, conduct a detailed inspection to verify compliance and safety. Check that scaffolding has a valid green inspection tag from a competent person indicating it has been inspected within the last 30 days and after any significant weather events. Verify the tag specifies safe working load appropriate for masonry work (minimum 50 kg/m² plus storage). Inspect platforms to confirm they are fully planked with maximum gaps of 25mm and no damaged or broken planks. Check edge protection including top rails at 900-1100mm height, midrails preventing objects falling through, and toeboards preventing tools or materials sliding off edges. Verify safe access via internal stairs, protected ladders with landing platforms every 6 metres, or other compliant access methods. Inspect scaffold base plates for solid footing without settlement, all bracing is in place and secure, and scaffold is tied to the structure at required intervals. Test scaffold stability by attempting to shift the structure - there should be no movement. Check for any modifications, missing components, or damage including bent or rusted components requiring repair. If any deficiencies are identified, do not access the scaffold and report immediately to the scaffold company for rectification.

Safety considerations

Never access scaffolding that does not have a valid green inspection tag or where you identify any safety concerns. Do not attempt repairs or modifications yourself - this must be performed by qualified scaffolders with appropriate licences. If you must work on scaffolding with concerns, implement additional fall protection through full-body harness connected to independent anchor points until deficiencies are rectified. Report all scaffold issues to supervisors immediately.

Material Delivery and Positioning at Working Height

Coordinate delivery and positioning of bricks, blocks, mortar, and other materials to minimise manual handling and optimise ergonomics. Where scaffolding is used, arrange for telehandler or forklift to lift pallets of bricks or blocks directly onto scaffold platforms at the working level, eliminating the need for workers to lift individual units from ground level. Position materials centrally on platforms to prevent overloading one area and maintain scaffold balance. For ground-level work, use telehandler or forklift to place material pallets on firm, level ground at the work position, avoiding the need to carry materials long distances. If mechanical placement is not feasible, establish material staging areas where labourers can transfer smaller quantities using wheelbarrows or trolleys rather than manual carrying. Set up mortar mixing station at convenient location with mixer on stable surface, sand and cement storage nearby, and water supply accessible. Position mortar boards or tubs on wheeled trolleys or elevated stands at hip to waist height, never on the ground requiring bending. Brief all workers on material locations, handling procedures, and requirements to use mechanical aids rather than manual lifting wherever possible. Ensure maximum quantities of stored materials on scaffold platforms do not exceed the safe working load specified on the inspection tag.

Safety considerations

Mechanical placement of materials is the primary control for preventing manual handling injuries. Do not lift materials from ground level when they can be delivered to working height mechanically. Use team lifting for blocks exceeding 20 kg with clear communication between lifters. Watch for pinch points when handling materials from pallets or stacks. Maintain clear access around stored materials to prevent trip hazards. Do not overload scaffold platforms with excessive material storage - calculate the weight of materials and ensure it remains below the safe working load. Secure materials on scaffold platforms to prevent wind displacement.

Setting Out and First Course Establishment

Accurate setting out is critical for quality outcomes and prevents rework that increases manual handling and time exposure to hazards. Begin by confirming wall positions from architectural drawings and transferring these to the foundation or slab using string lines, chalk lines, and spray paint markings. Use laser levels to establish level datum points at corners and at intervals along the wall position, accounting for any falls required for drainage. For external walls, verify damp proof course (DPC) membrane is correctly positioned before commencing brickwork. Spread a mortar bed approximately 10-15mm thick on the DPC or foundation, using a full-width bricklaying trowel. Lay corner bricks first, setting them precisely to established positions using a spirit level to confirm level in both directions and accurate height to datum. Connect corner bricks with a string line pulled tight between corners at the top outer edge of the brick to guide the first course. Lay bricks to the string line working from corners toward the centre, maintaining consistent joint thickness (typically 10mm). Tap bricks gently with a trowel handle to adjust position and level. Cut closure bricks as required to complete the course using a wet saw or angle grinder with water suppression to control dust. Check multiple times that the first course is perfectly level, correctly aligned, and at correct height as all subsequent courses will follow this datum. Any errors in the first course will compound through the wall height, requiring demolition and reconstruction.

Safety considerations

Setting out requires working at ground level for extended periods, creating manual handling and kneeling strain risk. Use knee pads to protect knees during ground-level work. When lifting bricks from packs, maintain neutral spine position by squatting rather than bending at the waist. Consider using a low adjustable platform to raise the first course materials to reduce bending. Ensure cutting equipment has functioning dust suppression and workers wear fitted P2 respirators during any cutting operations. Clean excess mortar from bricks immediately to prevent hardening and the need for grinding later which generates silica dust. If working on a slab with no edge protection, maintain awareness of edges and implement fall protection if edges are above 2 metres.

Laying Subsequent Courses with Height Progression

Once the first course is established and checked, proceed with laying subsequent courses working in a systematic pattern that maintains quality and safety. Apply a mortar bed to the previous course using a bricklaying trowel, creating a consistent 10mm bed across the width of the wall. Butter one end of each brick or block with mortar before positioning to create perpend (vertical) joints between units. Place each brick or block following the bond pattern specified in the drawings (typically stretcher bond for single-leaf walls or Flemish/English bond for double-leaf walls). Use the string line repositioned for each course to maintain alignment and consistent mortar joint thickness. Check level regularly using a spirit level, particularly at corners and window/door openings. As wall height increases, adjust working position by accessing scaffolding platforms or elevating work positions. Raise mortar boards to working height as courses progress, maintaining materials between hip and shoulder height to minimise bending and reaching. Continue building up corners first to act as guides for the wall between, typically constructing corners 4-6 courses higher than the intervening wall. Install lintels, weep holes, and ties at specified locations according to structural engineer's details and architectural requirements. When reaching upper scaffold lifts, verify edge protection remains in place and platforms are clear of excess materials before commencing work at that level. Maintain steady work pace without rushing, as fatigue increases injury risk and quality errors.

Safety considerations

As wall height increases, fall risks increase proportionally. Verify edge protection is intact before working at heights. Do not lean beyond edge protection or stand on materials to gain height. If working from scaffolding, ensure mortar boards and material packs are secured to prevent displacement. Implement work-rest cycles to prevent fatigue, particularly in hot weather. Drink water regularly with 200-250ml every 15-20 minutes during physical work. Watch for signs of heat stress in yourself and coworkers including dizziness, confusion, or nausea requiring immediate cooling and medical assessment. Maintain housekeeping by removing excess mortar droppings from platforms to prevent slip hazards.

Cutting and Fitting with Dust Control

Cutting bricks and blocks to fit openings, corners, and architectural features requires strict dust control to prevent silica exposure. Before commencing cutting, verify dust control systems are operational and workers have appropriate respiratory protection. For all cutting operations, use wet cutting methods as the primary control measure. Operate masonry brick saws with integrated water delivery systems that continuously flood the blade and cutting area, creating visible water flow and preventing dust generation. Ensure adequate water supply throughout cutting operations and top up as needed. For angle grinder use, attach dust shrouds connected to industrial vacuum extractors with HEPA filtration, confirming vacuum operation before commencing. Isolate cutting areas from general work areas using barrier screens to prevent dust migration. Mark cutting lines clearly on materials before cutting to ensure accuracy and prevent rework requiring additional cuts. Support materials firmly on saw tables or work benches before cutting, never handheld cutting. Wear fitted P2 or P3 respirators during all cutting operations even when wet methods are used, as they do not eliminate all dust. Safety glasses with side shields must be worn to protect against projectiles from cutting. Collect cut materials in designated bins or areas and clean cutting equipment regularly to prevent dust accumulation. If dry cutting is necessary in emergency situations where wet methods genuinely cannot be used, implement additional controls including isolation enclosures, multiple workers wearing P3 respirators, and air monitoring to confirm exposure remains below occupational exposure limits.

Safety considerations

Silica dust exposure is a serious long-term health hazard with no cure for silicosis once developed. Never bypass dust control measures to save time or because you find respirators uncomfortable. Wet cutting with adequate water flow combined with fitted respiratory protection provides effective control of respirable silica exposure. If you are unsure whether dust controls are adequate, request air monitoring to measure actual exposure levels. Cutting equipment creates multiple hazards including rotating blades, electric shock, noise, and vibration. Maintain full concentration during cutting operations and avoid distractions. Do not remove blade guards or safety devices. Disconnect power before changing blades or performing maintenance. Report any dust control equipment failures immediately and cease cutting until repairs are completed.

Pointing, Jointing, and Surface Finishing

Once brickwork or blockwork reaches the specified height or completion point, finish mortar joints to provide weatherproofing, aesthetics, and surface protection. For recessed or 'ironed' joints, use a pointing trowel to compress and shape joints while mortar is still workable, creating a smooth, slightly recessed profile. For struck or weathered joints, use a trowel to cut mortar at an angle directing water away from the joint. Ensure consistent joint profile throughout for aesthetic quality. If joints require repointing after initial set, rake out to a depth of 10-15mm using a joint raker or grinder fitted with dust control, then apply fresh mortar packed firmly into joints. Clean excess mortar from brick faces using a soft brush while mortar is still workable, avoiding smearing which can cause staining. For final cleaning, wait until mortar has partially cured (typically 24-48 hours) before washing down with water and soft bristle brushes. Avoid aggressive cleaning methods that can damage bricks or mortar. Apply mortar to weep holes where specified, leaving proper voids for drainage. Check all lintels, sills, and architectural features have proper mortar joints. Protect completed work from weather damage including rain, frost, and excessive sun during curing period by covering with plastic sheeting or hessian as appropriate. For blockwork that will receive render or plaster, ensure joints are either flush or slightly raked as specified.

Safety considerations

Pointing and finishing work involves sustained contact with alkaline mortar products creating cement burns and dermatitis risk. Wear chemical-resistant gloves throughout finishing operations and replace gloves when they become saturated with mortar. Wash any mortar splashes from skin immediately with clean water. Grinding to rake joints generates high levels of silica dust requiring strict controls including wet methods, on-tool extraction, and P2/P3 respirators. If working at heights during pointing, verify edge protection remains intact and maintain three points of contact when using tools. Repetitive pointing actions can cause hand and wrist strain - take short breaks and vary hand positions. Clean tools at the end of each day to prevent mortar hardening and requiring grinding to remove, which generates additional dust exposure.

Site Clean-up and Material Management

At the completion of each work period or at the end of the project phase, conduct thorough site clean-up to eliminate trip hazards, prevent environmental contamination, and prepare for the next shift or trade. Begin by removing all waste materials including broken bricks, mortar droppings, cut-offs, and packaging from work areas and scaffolding platforms. Use hand tools and brushes to collect waste rather than blowing or dry sweeping which creates dust. Place waste in designated bins or skips for disposal according to site waste management procedures. Remove excess materials from scaffolding platforms to prevent overloading and maintain clear access. Return unused bricks and blocks to ground storage or secure them on scaffold platforms if they will be used in the next shift. Clean mortar mixing equipment thoroughly including mixer drum, mortar boards, wheelbarrows, and tubs using water and brushes before mortar hardens. Clean all hand tools removing mortar residue, checking for damage, and storing tools securely. Coil hoses and cables to prevent trip hazards and protect from damage. Inspect PPE for damage or excessive wear and replace as necessary. Dispose of damaged or saturated gloves, used respirator filters, and damaged equipment appropriately. Document any incidents, near misses, or hazards identified during the shift in incident registers or safety log books. If work is incomplete, secure the site against unauthorised access, particularly preventing children or public accessing scaffolding or work areas. Update site diary or work records documenting progress and any issues requiring attention. Brief supervisors on work completed, materials required for next shift, and any safety concerns requiring action.

Safety considerations

Clean-up activities create manual handling, trip, and slip hazards requiring continued vigilance even at the end of shifts when workers are fatigued. Lift waste materials using proper technique or use mechanical aids for heavy loads. Do not dry sweep areas that have been subject to cutting as this creates silica dust exposure - use water for dust suppression during cleaning. Check that all power tools are disconnected before leaving site. Ensure water supplies are turned off to prevent freezing damage in cold weather. If working at heights during clean-up, maintain fall protection awareness and do not become complacent during routine tasks. Report all tools and equipment defects so repairs can be completed before the next shift. Proper housekeeping significantly reduces injury rates and demonstrates professional work practices.

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Frequently asked questions

What qualifications do I need to perform brick and block laying in Australia?

To work as a qualified bricklayer in Australia, you typically need to complete a Certificate III in Bricklaying/Blocklaying (CPC31020) through an apprenticeship program combining on-the-job training with formal technical education over 3-4 years. All construction workers must also hold a general construction induction card (White Card) by completing the CPCWHS1001 unit demonstrating knowledge of WHS requirements. For specific high-risk activities, additional qualifications are required: workers erecting, altering, or dismantling scaffolding must hold a Scaffolding Work High Risk Work Licence, those operating elevating work platforms over 11 metres need an EWP High Risk Work Licence, and workers using powder-actuated tools require specific certification. Supervisors should hold trade qualifications plus demonstrated competency in supervision and safety management. Some states may have additional licensing or registration requirements for builders and contractors.

How do I prevent silicosis from cutting bricks and blocks?

Preventing silicosis requires implementing multiple control measures following the hierarchy of control. First, eliminate cutting wherever possible by ordering pre-cut or sized materials and planning work to minimise cutting requirements. Where cutting is necessary, use wet cutting methods as the primary engineering control, with masonry saws equipped with water delivery systems that continuously flood the cutting area, creating visible water flow that suppresses dust at the source. For angle grinders, use dust shrouds connected to industrial vacuum extractors with Class M or H HEPA filtration, checking vacuum operation before each use. Isolate cutting areas from general work zones using barriers to prevent dust migration. As an administrative control, rotate workers to limit individual exposure duration and schedule cutting during periods with good natural ventilation. Provide fitted P2 or P3 respirators to all workers performing or working near cutting operations, with fit-testing to ensure adequate seal and protection factor. Implement health surveillance including baseline lung function testing and periodic chest X-rays for workers with regular exposure. Document all dust control measures in your SWMS and enforce their use strictly. Never perform dry cutting as a matter of convenience - it should only occur where wet methods genuinely cannot be used, with additional controls including respiratory protection upgraded to P3, air monitoring to confirm exposure limits are not exceeded, and minimised exposure duration.

What are my manual handling responsibilities as a bricklaying employer?

Under the Work Health and Safety Act 2011 and associated regulations, employers have a duty to eliminate or minimise manual handling risks so far as is reasonably practicable. For bricklaying operations, this requires first attempting to eliminate manual handling of heavy bricks and blocks through use of mechanical aids including telehandlers or forklifts to place material pallets at working height, scissor lifts to elevate materials to upper levels, brick tongs and grips allowing use of larger muscle groups, and vacuum lifters for large format units. Where manual handling cannot be eliminated, minimise risks by positioning materials between hip and shoulder height using elevated platforms and mortar boards, implementing team lifting for blocks exceeding 20kg, providing trolleys and wheelbarrows for horizontal transport, and rotating workers between manual handling and other tasks. Provide information, training, and instruction in correct manual handling techniques including maintaining neutral spine position, using leg muscles rather than back, avoiding twisting while loaded, and recognising early symptoms of injury. Consult with workers to identify problems with current manual handling practices and involve them in developing solutions. Monitor manual handling activities to identify workers adopting poor posture or technique requiring intervention. Provide early intervention including modified duties, physiotherapy access, and ergonomic assessment if workers report discomfort. Document all manual handling risk assessments and control measures in your SWMS and review regularly based on injury data and worker feedback.

How often does scaffolding need to be inspected for bricklaying work?

Scaffolding inspections occur at multiple levels with different frequencies. Initial inspection must be conducted by a competent person (typically the scaffold erector holding a High Risk Work Licence) immediately after erection is complete and before anyone is permitted to access the scaffold. This inspection verifies the scaffold has been erected according to design, all components are in place and secure, platforms are fully planked, edge protection is complete, and safe working loads are determined. The scaffold must be tagged with a green inspection tag displaying the inspection date, inspector name, safe working load, and next inspection due date. Regular inspections by a competent person are required at least every 30 days during extended use, after significant weather events (storms, high winds, heavy rain), after any modifications or alterations, if any components are damaged or missing, and when scaffold is to be used for a different purpose than originally designed. Daily pre-start inspections must be conducted by the supervisor or lead worker before work commences each day, checking for visible damage, missing components, overloading with materials, signs of instability or movement, integrity of edge protection, and valid inspection tag. If any concerns are identified during daily inspection, workers must not access the scaffold until a competent person conducts a detailed inspection and confirms safety or makes repairs. Document all scaffolding inspections in site records and take action immediately to address any identified deficiencies.

What should I do if mortar gets on my skin?

Immediate action is critical when mortar, cement, or concrete contacts skin due to the high alkalinity (pH 12-13) causing chemical burns. First, remove any contaminated gloves or clothing to prevent continued exposure. Immediately wash the affected area with copious amounts of clean water for at least 20 minutes, using a gentle stream from a hose or tap rather than high pressure which can drive chemicals deeper into tissue. Do not use harsh soaps, solvents, or attempt to neutralise the chemical with acids as this can cause additional reactions. After washing thoroughly, pat the area dry with clean cloth or paper towel. If skin shows redness, irritation, or discomfort after washing, seek first aid assessment and consider medical review, particularly if blistering develops. For eye splashes, immediately flush eyes with water using an eye wash station or gentle stream for at least 15 minutes, holding eyelids open to ensure water contacts all surfaces. Seek urgent medical attention for eye exposures even if symptoms seem mild, as delayed damage can occur. To prevent mortar contact, always wear chemical-resistant gloves (nitrile or neoprene) when handling wet cement products, apply barrier cream to hands before starting work, wear long-sleeved shirts to protect arms, and replace saturated gloves immediately. At the end of shifts, wash hands and exposed skin thoroughly, dry completely, and apply moisturiser to restore skin barrier function. If you experience persistent skin irritation, cracking, or redness despite preventive measures, see a doctor promptly as this may indicate developing dermatitis requiring medical treatment and workplace accommodation.

Can I work on scaffolding in high winds or storms?

Work on scaffolding must cease when weather conditions create unsafe situations. Specifically, evacuate scaffolding immediately if thunderstorms approach due to lightning strike risk from being on elevated metal structures. Do not work on scaffolding during rain as wet platforms become extremely slippery and visibility is reduced, creating fall hazards. For wind conditions, Australian Standards and most principal contractors require work on scaffolding to cease when sustained wind speeds reach 40 km/h or gusts exceed 60 km/h, as wind can cause instability, blow workers off balance, displace materials creating struck-by hazards, and generate dust affecting visibility and creating slip hazards. Check weather forecasts before commencing work each day and monitor Bureau of Meteorology warnings throughout the shift. If winds increase during work, secure all loose materials and tools, descend from scaffolding safely, and do not return until conditions improve. After storms, high winds, or heavy rain, scaffolding must be inspected by a competent person before work resumes to check for damage, instability, displaced components, and accumulated water or debris. Never attempt to work on scaffolding in extreme weather conditions thinking you can manage the risk - the consequences of falls from height are catastrophic and no schedule pressure justifies risking your life. Your right to refuse unsafe work is protected under WHS legislation Section 84, and you cannot be discriminated against for exercising this right.

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Brick and Block Laying Safe Work Method Statement

What this SWMS covers

Why this SWMS matters

Hazard identification

Control measures

Personal protective equipment

Step-by-step work procedure

Site Assessment and Work Area Preparation

Scaffold Inspection and Access Verification

Material Delivery and Positioning at Working Height

Setting Out and First Course Establishment

Laying Subsequent Courses with Height Progression

Cutting and Fitting with Dust Control

Pointing, Jointing, and Surface Finishing

Site Clean-up and Material Management

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