BlueSafe
Brick Manufacturing Risk Assessment

Brick Manufacturing Risk Assessment

  • • 100% Compliant with Australian WHS Acts & Regulations
  • • Fully Editable MS Word & PDF Formats Included
  • • Pre-filled Content – Ready to Deploy Immediately
  • • Customisable – Easily Add Your Logo & Site Details
  • • Includes 2 Years of Free Compliance Updates

Brick Manufacturing Risk Assessment

Product Overview

Identify and control organisational risks associated with Brick Manufacturing at a management and systems level, covering governance, plant, people, and process controls across your entire operation. This Risk Assessment supports executive Due Diligence, aligns with WHS legislation, and helps protect your business from regulatory enforcement, prosecution, and operational liability exposures.

Risk Categories & Hazards Covered

This document assesses risks and outlines management controls for:

  • WHS Governance, Legal Compliance and Consultation: Assessment of safety leadership, WHS policy framework, officer due diligence, consultation arrangements, and verification of compliance with statutory duties across brick manufacturing operations.
  • Plant Design, Procurement and Change Management: Management of risks arising from new plant selection, layout and guarding design, commissioning, and engineering change processes for kilns, conveyors, mixers, and packaging lines.
  • Machine Guarding, Interlocks and Functional Safety: Evaluation of fixed and interlocked guarding, light curtains, emergency stops, and safety-related control systems to ensure safe access, cleaning, clearing of jams, and maintenance activities.
  • Automation, Robotics and Control Systems Integration: Assessment of robotic stackers, automated handling systems, PLC controls, and system integration risks including unexpected start-up, interface failures, and control system modifications.
  • Materials Handling, Storage and Manual Handling of Bricks and Clay: Management of bulk clay reception, stockpiles, palletised brick handling, forklift use, and manual handling tasks to minimise musculoskeletal and crush injury risks.
  • Clay Preparation, Dust, Silica and Air Quality Management: Control of respirable crystalline silica, clay and refractory dust, local exhaust ventilation performance, housekeeping standards, and respiratory protective equipment programs.
  • Kiln Operation, High Temperature and Energy Systems: Assessment of kiln firing processes, refractory maintenance, thermal stress, combustion systems, gas and electrical energy sources, and safe start-up/shutdown procedures.
  • Chemical and Process Safety for Dipping Tanks and Additives: Management of glazes, colourants, additives and dipping tanks, including SDS review, hazardous chemical storage, bunding, spill control, and safe handling procedures.
  • Maintenance, Isolation and Contractor Management: Evaluation of lockout/tagout systems, isolation verification, permit-to-work processes, and contractor induction and supervision for shutdowns and high-risk maintenance.
  • Traffic, Yard Management and Loading Operations: Control of mobile plant interactions, segregation of pedestrians and vehicles, loading/unloading of bricks, and site traffic plans for internal and external transport interfaces.
  • Worker Competency, Training, Supervision and Behaviour: Assessment of competency requirements, licensing, induction content, supervision levels, and behavioural expectations for operators, maintenance personnel and contractors.
  • Fatigue, Work Scheduling and Psychosocial Risk Management: Management of shift work, overtime, workload, role clarity, bullying and harassment, and other psychosocial hazards within brick manufacturing environments.
  • Emergency Preparedness, Fire, Explosion and Incident Response: Evaluation of emergency plans, fire and explosion controls for kilns and gas systems, evacuation drills, first aid capability, and incident escalation protocols.
  • Health Monitoring, Injury Management and Continuous Improvement: Systems for health surveillance (including silica exposure), early reporting of symptoms, rehabilitation and return to work, and ongoing review of WHS performance data.

Who is this for?

This Risk Assessment is designed for Business Owners, Operations Managers, Safety Managers and WHS Advisors responsible for planning, overseeing and continuously improving brick manufacturing operations across one or multiple sites.

Hazards & Risks Covered

Hazard Risk Description
1. WHS Governance, Legal Compliance and Consultation
  • • Lack of documented WHS management system aligned with WHS Act 2011 and WHS Regulations
  • • Inadequate senior management commitment and resourcing for WHS in brick manufacturing operations
  • • Failure to consult with workers, health and safety representatives (HSRs) and contractors on changes to plant, processes and materials
  • • Poor integration of WHS into business planning, procurement and production targets (e.g. prioritising output over safety in kiln and press operations)
  • • No systematic review of compliance against relevant Australian Standards (e.g. AS 4024 series for machinery, AS/NZS 4801 / ISO 45001 style systems)
  • • Inadequate processes for managing officer due diligence obligations and WHS responsibilities for managers and supervisors
  • • Lack of documented, up-to-date WHS policies, procedures and codes of practice specific to brick and clay manufacturing plant
2. Plant Design, Procurement and Change Management
  • • Procurement of brick presses, extruders, cutters, robots and kilns that are not compliant with Australian Standards or lack adequate guarding and safety interfaces
  • • Inadequate pre-purchase risk assessment for new or refurbished equipment such as Hampton Extruders, Wallbank Presses, Welko Presses and Bickley Kilns
  • • Uncontrolled modifications to plant (e.g. bypassing interlocks, altering guarding, changing control logic) without engineering review
  • • Failure to integrate safety systems when combining equipment (e.g. pug mill feeding extruder, extruder feeding Freymatic cutter and pack robot)
  • • Missing or incomplete technical documentation, OEM manuals and functional safety data for imported plant
  • • Poor consideration of ergonomics and access for cleaning, adjustments and maintenance at design stage
  • • Lack of lifecycle planning for plant replacement, upgrades and decommissioning of obsolete brick presses and kilns
3. Machine Guarding, Interlocks and Functional Safety
  • • Inadequate fixed and interlocked guarding on brick air presses, friction presses, Wallbank and Welko presses, and Hampton extruders
  • • Access to in-running nip points, pinch points and crush zones on conveyors, pug mills, Freymatic cutters and pack unloading robots
  • • Bypassing or defeating interlocks, light curtains or safety mats through poor design or production pressure
  • • Single-channel or unreliable emergency stop systems across linked plant (extruder–cutter–robot–pallet wrapper line)
  • • Lack of validation and periodic testing of safety-related control systems (e.g. safety PLCs, interlocks, rope pulls)
  • • Inadequate perimeter guarding and access control around the brick pack unloading robot and pallet wrapping machine
  • • Uncontrolled access to hazardous areas during cleaning, jam-clearing and set-up activities
4. Automation, Robotics and Control Systems Integration
  • • Control system failures leading to unexpected start-up or movement of the brick pack unloading robot, pallet wrapping machine and associated conveyors
  • • Poor integration between legacy presses/extruders and newer robotic or automated handling systems
  • • Software changes or updates to PLCs, HMIs or safety controllers without appropriate testing and validation
  • • Inadequate control of operating modes (automatic, manual, maintenance, set-up) allowing unsafe access during motion
  • • Lack of clear responsibility for control system design, configuration management and cybersecurity
  • • Inadequate fault diagnostics leading to unsafe workarounds by operators (e.g. defeating safety devices to overcome nuisance trips)
  • • Loss of control integrity after plant expansions or modifications to the brick handling lines
5. Materials Handling, Storage and Manual Handling of Bricks and Clay
  • • Ineffective systems for handling heavy and awkward loads such as green bricks, fired bricks and pallets, leading to musculoskeletal disorders
  • • Uncontrolled stacking, storage and racking of bricks causing collapse or falling objects
  • • Inadequate design and maintenance of mechanical handling equipment (forklifts, clamp attachments, conveyors, cranes) used around brick setting and unloading
  • • Poor layout around the brick setting of green product, pack unloading and pallet wrapping areas creating congestion and unsafe pedestrian–vehicle interactions
  • • Insufficient training and competency assessment for forklift and mobile plant operators
  • • Lack of engineering solutions for repetitive manual handling tasks such as brick dipping or rework handling
6. Clay Preparation, Dust, Silica and Air Quality Management
  • • Generation of respirable crystalline silica dust from clay preparation, pug mills, Bradley wet presses, friction presses, extruders and cutting processes
  • • Ineffective local exhaust ventilation (LEV) and enclosures around high dust-generating equipment and transfer points
  • • Poor housekeeping and dry sweeping leading to re-suspension of fine dust around kilns, presses and brick setting areas
  • • Inadequate air monitoring regime to verify compliance with workplace exposure standards for respirable crystalline silica and general dust
  • • Inappropriate selection, fit-testing or maintenance of respiratory protective equipment where required
  • • Lack of worker health monitoring and surveillance for silica-related illnesses
7. Kiln Operation, High Temperature and Energy Systems
  • • Exposure to extreme heat, hot surfaces and radiant energy from Bickley kilns and associated flues and ducting
  • • Uncontrolled release of gas or fuel used to fire kilns, including leaks and ignition sources
  • • Failure of kiln safety interlocks, flame detection and gas train safety devices
  • • Inadequate management of kiln maintenance, refractory repairs and access to confined or restricted spaces around kiln structures
  • • Thermal stress and dehydration for workers operating or maintaining kilns in high ambient temperatures
  • • Uncontrolled cooling of hot bricks leading to thermal shock and potential projectile or structural failures in stacking systems
8. Chemical and Process Safety for Dipping Tanks and Additives
  • • Exposure to hazardous chemicals in brick dipping tanks (e.g. coatings, sealants, anti-efflorescence agents) through skin contact, inhalation or splashes
  • • Inadequate bunding, containment and spill response arrangements around dipping tanks and chemical storage
  • • Improper mixing, dilution or temperature control of dipping solutions leading to chemical reactions or off-gassing
  • • Absence of up-to-date Safety Data Sheets (SDS) and inadequate risk assessments for new or substituted chemical products
  • • Incompatible chemical storage and transfer systems used across the brick finishing processes
  • • Inadequate ventilation around dipping tank areas leading to accumulation of vapours
9. Maintenance, Isolation and Contractor Management
  • • Maintenance work on presses, extruders, cutters, pug mills, kilns and robots without effective isolation and lock out tag out procedures
  • • Unplanned breakdown work under production pressure leading to shortcuts and exposure to live plant, hot surfaces or hazardous energy
  • • Poor coordination and supervision of specialist contractors working on kilns, robots, hydraulic systems or high-voltage electrical equipment
  • • Inadequate maintenance planning and scheduling resulting in deterioration of safety-critical components (guards, interlocks, brakes, limit switches)
  • • Lack of competence verification for maintenance personnel performing complex tasks on presses and automated systems
  • • Absence of permit-to-work systems for high-risk maintenance activities (working at height, confined spaces, hot work near kilns or combustible dust)
10. Traffic, Yard Management and Loading Operations
  • • Interaction between forklifts, trucks and pedestrians in brick yards, loading areas and around the brick pack unloading robot output zone
  • • Poorly designed traffic routes, blind corners and inadequate signage around storage of finished bricks and raw materials
  • • Uncontrolled loading and unloading of trucks carrying heavy brick packs and pallets, leading to falls of loads or vehicle instability
  • • Insufficient management of external transport contractors and visitors on site
  • • Inadequate lighting of yard areas during early morning, night or poor weather operations
  • • Fatigue and distraction among mobile plant operators due to long shifts and repetitive tasks
11. Worker Competency, Training, Supervision and Behaviour
  • • Insufficient training in the safe use of complex plant such as Hampton extruders, Bradley wet presses, Wallbank and Welko presses, Freymatic cutters and pack robots
  • • Over-reliance on informal on-the-job training without assessment of competence
  • • Inadequate supervision of new or inexperienced workers in high-risk areas like kilns, presses, dipping tanks and robot cells
  • • Lack of understanding of WHS obligations, risk controls and emergency procedures among workers and contractors
  • • Negative safety culture, tolerance of shortcuts, and production incentives that discourage reporting of hazards or near misses
  • • Language, literacy or cultural barriers preventing effective training and consultation
12. Fatigue, Work Scheduling and Psychosocial Risk Management
  • • Extended shifts, night work and rotating rosters in kiln operations and continuous pressing/packing lines leading to fatigue-related decision errors
  • • High production pressure resulting in stress, reduced risk perception and increased likelihood of unsafe behaviours
  • • Insufficient breaks and recovery time for workers in high-heat environments near kilns and heavy manual handling areas
  • • Poor management of psychosocial hazards including bullying, conflict and lack of role clarity in multi-shift operations
  • • Lack of systems to identify and support workers who may be experiencing mental health concerns impacting safe performance
13. Emergency Preparedness, Fire, Explosion and Incident Response
  • • Fire and explosion risks from gas-fired kilns, combustible dust accumulations and electrical equipment near clay and brick handling systems
  • • Inadequate emergency response procedures for kiln incidents, gas leaks, major plant failures or structural collapses of brick stacks
  • • Insufficient emergency egress routes and signage around complex plant layouts (press halls, kiln areas, robotics cells, dipping tank rooms)
  • • Poorly maintained fire detection and suppression systems, extinguishers and hydrants
  • • Lack of coordination with emergency services regarding site-specific hazards such as kilns, gas mains and high-voltage equipment
14. Health Monitoring, Injury Management and Continuous Improvement
  • • Delayed identification of occupational illnesses related to silica exposure, noise, vibration and heat stress
  • • Fragmented or inconsistent incident reporting, leading to underestimation of risk and missed learning opportunities
  • • Inadequate systems for early intervention and return to work following injuries in brick pressing, handling or kiln operations
  • • Failure to analyse trends in near misses, injuries and equipment failures across presses, extruders, kilns and robotics
  • • Lack of worker involvement in reviewing and improving WHS controls

Need to add specific hazards for your workplace?

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Legislation & References

This document was researched and developed to align with:

  • Work Health and Safety Act 2011
  • Work Health and Safety Regulations 2017
  • Model Code of Practice – How to Manage Work Health and Safety Risks: Guidance on systematic risk management processes.
  • Model Code of Practice – Managing Risks of Plant in the Workplace: Requirements for plant design, guarding, isolation and maintenance.
  • Model Code of Practice – Managing Risks of Hazardous Chemicals in the Workplace: Controls for storage, handling and use of glazes, additives and cleaning agents.
  • Model Code of Practice – Managing the Risks of Airborne Contaminants in the Workplace: Guidance on dust, silica and fume exposure control.
  • Model Code of Practice – Managing the Risk of Falls at Workplaces: Controls for work at height during maintenance, inspections and access to kilns or plant.
  • Model Code of Practice – Work Health and Safety Consultation, Cooperation and Coordination: Requirements for worker engagement and contractor interfaces.
  • AS/NZS ISO 45001:2018: Occupational health and safety management systems — Requirements with guidance for use.
  • AS/NZS ISO 31000:2018: Risk management — Guidelines
  • AS 4024 series – Safety of Machinery: Standards for machine guarding, interlocks and functional safety of machinery and automated systems.
  • AS/NZS 1715 & 1716: Selection, use and maintenance of respiratory protective equipment and performance requirements.
  • AS 1940: The storage and handling of flammable and combustible liquids, where applicable to fuels and certain additives.
Standard Risk Assessment Features (Click to Expand)
  • Comprehensive hazard identification for all activities
  • Risk rating matrix with likelihood and consequence analysis
  • Existing control measures evaluation
  • Residual risk assessment after controls
  • Hierarchy of controls recommendations
  • Action priority rankings
  • Review and monitoring requirements
  • Consultation and communication records
  • Legal compliance references
  • Sign-off and approval sections

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