Product Overview

Summary: This Manual Handling in Masonry SOP provides clear, practical guidance for safely lifting, carrying, and positioning bricks, blocks, stone and related masonry materials. It helps masonry businesses and contractors control musculoskeletal injury risks, meet Australian WHS obligations, and maintain productivity on site without compromising worker wellbeing.

Manual handling is one of the highest risk activities in masonry work, where workers routinely lift, carry and manoeuvre heavy bricks, blocks, lintels, bags of cement, and stone in often awkward positions. Without a structured approach, these repetitive and forceful tasks can quickly lead to sprains, strains, back injuries and long-term musculoskeletal disorders, as well as dropped loads, crush injuries and reduced productivity. This Manual Handling in Masonry Safe Operating Procedure provides a clear, step‑by‑step framework for planning, performing and supervising manual handling tasks specific to masonry work, both on construction sites and in yard or workshop environments.

The SOP translates Australian WHS requirements into practical controls that can be applied on any masonry job, from small residential builds to large commercial projects. It covers job planning, load assessment, use of mechanical aids (such as trolleys, hoists and forklifts), safe lifting techniques, team lifts, work layout and housekeeping, as well as communication and reporting of hazards or discomfort. By implementing this procedure, businesses can standardise safe work practices across crews, support effective training and inductions, and demonstrate due diligence to principal contractors, clients and regulators. The result is fewer injuries, more sustainable work practices for ageing workforces, and a more efficient, professional masonry operation.

Key Benefits

• Reduce the risk of musculoskeletal injuries from repetitive lifting, carrying and bending in masonry tasks.
• Ensure compliance with Australian WHS legislation and guidance on hazardous manual tasks in construction.
• Standardise safe manual handling techniques and expectations across all masonry workers and subcontractors.
• Improve productivity by planning work layouts, delivery points and mechanical aids to minimise unnecessary handling.
• Support effective training, inductions and toolbox talks with a clear, documented procedure tailored to masonry work.

Who is this for?

• Bricklayers
• Stonemasons
• Blocklayers
• Construction Labourers
• Site Supervisors
• Leading Hands
• WHS Advisors and Coordinators
• Construction Project Managers
• Small Masonry Business Owners
• Health and Safety Representatives (HSRs)

Hazards Addressed

• Musculoskeletal disorders from repetitive lifting, twisting and bending
• Back, shoulder and knee strains from handling heavy bricks, blocks and stone
• Crush injuries to hands and feet from dropped masonry units and lintels
• Overexertion injuries from carrying loads over uneven or sloping ground
• Fatigue-related incidents due to prolonged manual handling in hot or cold conditions
• Trips and slips while carrying loads through cluttered or poorly maintained work areas
• Impact injuries from unstable stacked bricks, blocks or pallets collapsing
• Manual handling risks associated with handling formwork, scaffolding components and masonry tools

Included Sections

• 1.0 Purpose and Scope – Application to masonry work, yards and construction sites
• 2.0 Definitions – Hazardous manual tasks, high-risk postures, team lifts, mechanical aids
• 3.0 Roles and Responsibilities – PCBUs, site supervisors, workers and subcontractors
• 4.0 Planning Manual Handling in Masonry – Job set-up, delivery coordination and layout design
• 5.0 Hazard Identification and Risk Assessment – Masonry-specific manual handling risks
• 6.0 Risk Control Measures – Elimination, substitution, engineering, administrative controls and PPE
• 7.0 Use of Mechanical Aids – Trolleys, pallet jacks, hoists, forklifts and block carriers
• 8.0 Safe Lifting and Carrying Techniques – Bricks, blocks, stone, lintels and bagged materials
• 9.0 Team Lifting Procedures – Communication, coordination and load distribution
• 10.0 Work Environment and Housekeeping – Access ways, stacking, storage and lighting
• 11.0 Fatigue, Environmental and Personal Factors – Heat, cold, hydration and fitness for work
• 12.0 Training, Induction and Supervision – Competency requirements and refresher training
• 13.0 Incident, Discomfort and Near-Miss Reporting – Early intervention and corrective actions
• 14.0 Monitoring, Review and Continuous Improvement – Inspections, audits and consultation
• 15.0 References and Related Documents – WHS legislation, Codes of Practice and internal policies

Legislation & References

• Model Work Health and Safety Act
• Model Work Health and Safety Regulations – Part 4.2 Hazardous Manual Tasks
• Safe Work Australia – Code of Practice: Hazardous Manual Tasks
• Safe Work Australia – Construction Work Code of Practice
• AS/NZS 45001:2018 Occupational health and safety management systems
• Safe Work Australia – Guide for Preventing Musculoskeletal Disorders in the Workplace