Product Overview

Summary: This Masonry Arch Construction Safe Operating Procedure provides a clear, step‑by‑step method for building masonry arches safely, accurately and in line with Australian WHS requirements. It integrates structural best practice with practical site controls, helping you deliver durable arches while protecting workers from high‑risk activities such as working at height, manual handling and collapse hazards.

Masonry arch construction is a specialised task that combines traditional trade skills with significant structural and safety considerations. Poorly planned or executed arch work can lead to formwork failure, premature load transfer, falling masonry and long‑term structural defects. This Safe Operating Procedure sets out a consistent, defensible method for planning, setting out, constructing and curing masonry arches on Australian worksites, with a strong focus on hazard identification, control measures and compliance with WHS obligations.

The document walks your team through each phase of the activity – from pre‑start planning, design verification and inspection of centring, through to placing units, managing mortar joints, striking formwork and final clean‑up. It clearly defines roles and responsibilities, required competencies, PPE, tools and equipment, and safe work methods for tasks such as handling heavy masonry, working from scaffolds and managing temporary supports. By implementing this SOP, businesses can reduce the risk of structural instability, injuries and rework, while demonstrating due diligence to clients, principal contractors and regulators.

For Australian construction businesses, this SOP also supports integration into broader safety management systems and quality assurance processes. It helps align site practices with relevant Australian Standards, builder specifications and engineering requirements, making it easier to induct new workers, standardise subcontractor performance and provide documented evidence of safe systems of work during audits or incident investigations.

Key Benefits

• Ensure a consistent, structurally sound method for masonry arch construction across all projects.
• Reduce the risk of collapse, falling objects and manual handling injuries during arch works.
• Demonstrate compliance with Australian WHS legislation and relevant construction standards.
• Streamline training and onboarding for bricklayers, apprentices and subcontractors.
• Minimise rework, defects and delays caused by poor set‑out, support or workmanship.

Who is this for?

• Bricklayers
• Stonemasons
• Site Supervisors
• Construction Project Managers
• WHS Advisors and Safety Officers
• Leading Hands and Forepersons
• Apprentice Bricklayers and Trainees
• Civil and Structural Contractors
• Residential and Commercial Builders

Hazards Addressed

• Collapse of temporary supports, centring or formwork during construction or striking
• Falling bricks, blocks or stone from height during placement or adjustment
• Manual handling injuries from lifting and positioning heavy masonry units and formwork components
• Falls from height when working on scaffolds, elevated platforms or ladders
• Trips and slips on uneven, cluttered or mortar‑contaminated work areas
• Exposure to cement and lime in mortar causing skin and eye irritation or burns
• Use of power tools (cut‑off saws, grinders, drills) generating dust, noise and kickback risks
• Silica dust exposure from cutting or grinding masonry units
• Struck‑by incidents involving moving plant such as forklifts, telehandlers or cranes used for lifting materials
• Premature loading of the arch resulting in structural instability or failure

Included Sections

• 1.0 Purpose and Scope
• 2.0 Definitions and Terminology (Arches, Centring, Springing Line, Rise, Span)
• 3.0 Roles, Responsibilities and Competency Requirements
• 4.0 Applicable Legislation, Standards and Codes of Practice
• 5.0 Required Tools, Equipment and Materials
• 6.0 Personal Protective Equipment (PPE) Requirements
• 7.0 Pre‑Start Planning and Risk Assessment (SWMS, JSEA)
• 8.0 Design Verification and Documentation (Engineer Details, Shop Drawings)
• 9.0 Site Preparation, Access and Housekeeping
• 10.0 Scaffolding, Platforms and Work at Height Controls
• 11.0 Setting Out the Masonry Arch (Dimensions, Templates and Control Lines)
• 12.0 Installation and Inspection of Centring/Formwork and Temporary Supports
• 13.0 Mortar Mixing, Handling and Application for Arches
• 14.0 Safe Handling and Placement of Masonry Units
• 15.0 Construction Sequence for Masonry Arches (Springers to Keystone)
• 16.0 Curing, Protection and Premature Load Prevention
• 17.0 Striking and Removal of Centring/Formwork
• 18.0 Quality Control, Tolerances and Defect Rectification
• 19.0 Hazard Identification and Control Measures (Collapse, Falling Objects, Manual Tasks, Dust)
• 20.0 Emergency Procedures and Incident Reporting
• 21.0 Environmental Considerations (Dust, Slurry and Waste Management)
• 22.0 Training, Induction and Competency Records
• 23.0 Inspection, Monitoring and Review of the Procedure
• 24.0 Document Control and Version History

Legislation & References

• Model Work Health and Safety Act 2011 (Cth)
• Model Work Health and Safety Regulations 2011 (Cth)
• Safe Work Australia – Code of Practice: Construction Work
• Safe Work Australia – Code of Practice: Managing the Risk of Falls at Workplaces
• Safe Work Australia – Code of Practice: Hazardous Manual Tasks
• AS 3700: Masonry structures
• AS 4773.1: Masonry in small buildings – Design
• AS 4773.2: Masonry in small buildings – Construction
• AS/NZS 1576 series: Scaffolding
• AS/NZS 4576: Guidelines for scaffolding
• AS 3600: Concrete structures (for lintels, supports and interaction with concrete elements)
• AS/NZS 1715: Selection, use and maintenance of respiratory protective equipment
• AS/NZS 1801: Occupational protective helmets
• AS/NZS 2161 series: Occupational protective gloves
• AS/NZS 2210 series: Safety, protective and occupational footwear