Product Overview

Summary: This Safe Operating Procedure sets out a safe, consistent method for constructing cavity walls on Australian building sites, from set-out to final inspection. It helps builders control structural, fall and manual handling risks while delivering compliant, high‑quality masonry that stands up to local conditions and WHS obligations.

Cavity wall construction is a core activity on residential and commercial building sites across Australia, yet it carries significant structural and safety risks if not tightly controlled. This Safe Operating Procedure provides a clear, step‑by‑step method for planning, setting out and constructing cavity walls, with a strong focus on safe work sequencing, temporary support, and quality checkpoints. It addresses common issues such as unstable partially built walls, inadequate ties and damp-proofing, poor cavity cleanliness, and unsafe access around scaffolds and working platforms.

By implementing this SOP, construction businesses can standardise how cavity walls are built across different crews and projects, reducing rework, defects and WHS incidents. It supports compliance with Australian building codes and WHS legislation by embedding hazard identification, risk controls, and inspection points directly into the work process. The document is designed to be practical for use on site—supporting toolbox talks, apprentice training and daily pre‑start briefs—while also providing management with a defensible, documented system of work for audits, client requirements and regulator inspections.

Key Benefits

• Ensure a consistent, compliant method for cavity wall construction across all projects and crews.
• Reduce the risk of wall collapse, falls, manual handling injuries and other site incidents during masonry works.
• Improve build quality by embedding checks for wall alignment, cavity width, damp-proofing, insulation and tie installation.
• Streamline training and onboarding for new workers and apprentices with a clear, step-by-step procedure.
• Demonstrate due diligence and WHS compliance during regulator visits, client audits and defect inspections.

Who is this for?

• Site Supervisors
• Construction Project Managers
• Bricklayers and Blocklayers
• Leading Hands and Forepersons
• WHS Advisors and Safety Officers
• Apprentice Coordinators
• Residential and Commercial Builders
• Quality Assurance Managers in Construction

Hazards Addressed

• Collapse of partially constructed walls due to inadequate bracing or poor construction sequence
• Falls from height when working on scaffolds, trestles or incomplete floors adjacent to cavity walls
• Struck-by injuries from falling bricks, blocks, tools or materials
• Manual handling injuries from repetitive lifting and handling of bricks, blocks, lintels and mortar bags
• Trips and slips on uneven or cluttered work areas, scaffold decks and access routes
• Exposure to cement dust and silica from cutting bricks or blocks
• Hand and finger injuries from bricklaying tools, sharp ties and reinforcement
• Musculoskeletal strain from awkward postures and sustained reaching over cavities
• Weather-related risks such as high winds affecting tall, unbraced walls or wet conditions causing slips
• Noise exposure from power tools used in cutting and fixing operations

Included Sections

• 1.0 Purpose and Scope
• 2.0 Definitions and References
• 3.0 Roles and Responsibilities
• 4.0 Required Competencies and Training
• 5.0 Tools, Plant and Materials
• 6.0 Personal Protective Equipment (PPE) Requirements
• 7.0 Pre-Start Planning and Site Preparation
• 8.0 Hazard Identification and Risk Controls for Cavity Wall Construction
• 9.0 Set-Out, Footings and Base Preparation
• 10.0 Construction of Inner and Outer Leaves
• 11.0 Installation of Wall Ties, Damp-Proof Courses and Flashings
• 12.0 Cavity Width, Cleanliness and Insulation Placement
• 13.0 Lintels, Control Joints and Structural Restraint
• 14.0 Working at Height and Scaffolding Requirements
• 15.0 Manual Handling and Material Handling Procedures
• 16.0 Use of Power Tools and Cutting Equipment
• 17.0 Weather, Wind and Temporary Bracing Controls
• 18.0 Quality Control Checks and Inspection Hold Points
• 19.0 Housekeeping and Waste Management
• 20.0 Emergency Procedures and Incident Reporting
• 21.0 Documentation, Records and Review

Legislation & References

• Model Work Health and Safety Act and Regulations (as implemented in each state and territory)
• Safe Work Australia – Code of Practice: Construction Work
• Safe Work Australia – Code of Practice: Managing the Risk of Falls at Workplaces
• AS 3700: Masonry structures
• AS 4773.1: Masonry in small buildings – Design
• AS 4773.2: Masonry in small buildings – Construction
• AS/NZS 1576: Scaffolding (series)
• AS/NZS 4455: Masonry units, pavers, flags and segmental retaining wall units
• AS/NZS 1715: Selection, use and maintenance of respiratory protective equipment
• AS/NZS 1801: Occupational protective helmets