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Brick And Block Laying Risk Assessment

Brick And Block Laying Risk Assessment

  • • 100% Compliant with Australian WHS Acts & Regulations
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Brick And Block Laying Risk Assessment

Product Overview

Identify and control organisational risks associated with Brick and Block Laying through a structured, management‑level WHS Risk Management framework that focuses on planning, systems, and governance rather than task-by-task procedures. This Risk Assessment supports compliance with the WHS Act, demonstrates executive Due Diligence, and helps protect your business from regulatory and operational liability.

Risk Categories & Hazards Covered

This document assesses risks and outlines management controls for:

  • WHS Management, Governance and Legal Compliance: Assessment of leadership responsibilities, safety governance structures, consultation arrangements, and alignment with statutory duties for brick and block laying operations.
  • Planning, Design and Pre‑Construction Coordination: Management of design-stage decisions, constructability reviews, interfaces with other trades, and pre‑start coordination to minimise downstream safety and structural risks.
  • Procurement of Materials, Plant and Equipment: Evaluation of supplier selection, specification of compliant masonry materials, mortar products, scaffolds, and bricklaying equipment, including verification of conformity with Australian Standards.
  • Contractor and Worker Competency, Training and Licensing: Controls for verifying trade qualifications, high risk work licences, VOC processes, and ongoing training in brick and block laying hazards such as silica, manual handling and work at height.
  • Safe Work Procedures, SWMS and Work Method Standardisation: Oversight of documented procedures and SWMS for brick and block laying, ensuring consistency, version control, and integration with broader site safety management systems.
  • Supervision, Coordination and Site Control: Assessment of supervisory competence, span of control, communication pathways, and coordination of concurrent works affecting masonry activities and structural stability.
  • Material Handling, Storage and Logistics Systems: Management of palletised bricks and blocks, mortar deliveries, lay‑down areas, traffic flows, and mechanical handling systems to reduce crush, strike and manual handling risks.
  • Plant, Equipment and Maintenance Management: Controls for selection, inspection and maintenance of brick saws, mixers, hoists, scaffolding components and lifting devices, including pre‑use checks and defect management.
  • Health Risk Management (Silica, Chemicals, Noise and Ergonomics): Assessment of exposure to respirable crystalline silica from cutting and chasing, cement-based products, noise from powered equipment, and repetitive or forceful tasks impacting musculoskeletal health.
  • Working at Heights, Scaffolding and Structural Stability Systems: Governance of scaffold design and certification, edge protection, access systems, and temporary bracing to maintain stability of partially completed brick and block walls.
  • Incident Reporting, Investigation and Corrective Action: Systems for capturing near misses and incidents, conducting root cause analysis, and implementing corrective and preventive actions specific to masonry works.
  • Monitoring, Audit and Continuous Improvement: Frameworks for inspections, internal audits, performance metrics, and management review to drive ongoing improvement in brick and block laying safety performance.

Who is this for?

This Risk Assessment is designed for Business Owners, Construction Managers, Project Managers and Safety Officers responsible for planning, overseeing and governing brick and block laying activities across projects or business units.

Hazards & Risks Covered

Hazard Risk Description
1. WHS Management, Governance and Legal Compliance
  • • Absence of a documented WHS Management System specific to brick and block laying, leading to inconsistent safety practices across projects
  • • Failure to align policies and procedures with WHS Act 2011, WHS Regulations and relevant Codes of Practice (e.g. construction work, hazardous manual tasks, noise, managing risks of falls)
  • • Inadequate allocation of WHS responsibilities between PCBU, officers, site supervisors and subcontract bricklaying crews
  • • Insufficient consultation, cooperation and coordination between principal contractor, bricklaying subcontractors and other trades sharing the workplace
  • • Lack of formal risk management process for brick and block laying hazards such as core filled block work, block splitting, brick saw use, masonry cleaning and Hebel construction
  • • Poor change management when introducing new products (e.g. Hebel systems), methods or equipment, resulting in unmanaged system risks
  • • Failure to review and update WHS documents after incidents, regulatory changes or lessons learned
2. Planning, Design and Pre‑Construction Coordination
  • • Insufficient design consideration for safe brick and block laying, including access for core filling, positioning of damp course, and installation of wall ties
  • • Lack of early coordination with structural engineers and designers regarding safe construction sequencing of external leaf walls and Hebel systems
  • • Inadequate planning of material delivery locations and lay‑down areas leading to unstable brick stacks, poor access and increased crush injury risk
  • • No systematic review of drawings and specifications for buildability and safety implications (e.g. high level face brickwork, exposed brickwork needing additional cleaning)
  • • Poor planning for working at heights for upper courses of brick and block walls, leading to last‑minute and non‑compliant access arrangements
  • • Failure to identify environmental constraints (noise restrictions for brick saws, slurry and wash‑water management from brick and masonry cleaning)
  • • Inadequate consideration of interface risks between bricklaying crews and other trades operating near scaffolds, hoists and materials loading zones
3. Procurement of Materials, Plant and Equipment
  • • Procurement of substandard bricks, blocks or Hebel units with inconsistent dimensions or defects increasing breakage, cutting and manual handling effort
  • • Ordering excessive quantities of bricks and blocks without considering available safe storage space, contributing to unstable stacks and crush injury risk
  • • Sourcing brick grips, clamps and lifting attachments that are not rated or compatible with the specific masonry units, increasing risk of dropped loads
  • • Procurement of brick saws, cutting equipment and dust control systems that lack appropriate guarding, water suppression or dust extraction to manage silica exposure
  • • Selection of cleaning chemicals and masonry cleaning systems without assessing corrosiveness, fume generation and compatibility with surfaces and controls
  • • Acquisition of wheelbarrows, trolleys and mechanical aids with poor ergonomic design, increasing strain during transporting bricks and mortar
  • • Failure to specify noise‑reduced equipment or accessories, resulting in higher noise exposure from saws and mechanical plant
4. Contractor and Worker Competency, Training and Licensing
  • • Engagement of bricklaying subcontractors without verification of competency, licences and WHS performance history
  • • Insufficient training in safe systems of work for core filled block laying, Hebel construction, brick splitting or dressing, joint raking and masonry cleaning
  • • Lack of formal competency in use of brick saws, including blade change procedures, dust controls and manual handling of heavy units during cutting
  • • Inadequate instruction on safe stacking of bricks and blocks, leading to instability and potential crush injuries from toppled stacks
  • • Poor understanding of correct use of brick grips, clamps and other specialised lifting tools, increasing dropped object risk
  • • Limited training in recognising and controlling silica dust exposure from cutting, raking joints and cleaning masonry surfaces
  • • Absence of induction on site‑specific hazards such as external leaf wall stability, temporary bracing requirements and safe fixing of wall ties and damp course
  • • No refreshers or verification of competency for long‑serving workers who may rely on outdated or unsafe practices
5. Safe Work Procedures, SWMS and Work Method Standardisation
  • • Lack of documented safe work procedures or SWMS for systemic brick and block laying activities, leading to variable work practices between crews and projects
  • • SWMS that focus only on basic bricklaying and fail to address specialised tasks such as core filling, Hebel installation, masonry cleaning, brick saw use and joint raking
  • • Procedures that over‑emphasise task steps without addressing underlying system controls such as supervision, permit systems, inspection regimes and emergency response
  • • Inadequate consultation with bricklayers and labourers when developing procedures, resulting in documents that are impractical and routinely ignored
  • • Failure to integrate requirements for safe stacking, storage and handling of bricks and blocks into documented methods, increasing risk of toppled stacks and crush injuries
  • • No standard procedure governing maximum manual lift weights, use of mechanical aids and team lifts for transporting bricks, blocks and mortar
  • • SWMS documents not reviewed or updated when site conditions or construction sequences change
6. Supervision, Coordination and Site Control
  • • Insufficient on‑site supervision of bricklaying teams, allowing unsafe practices such as over‑stacking bricks, improper use of brick grips and ad‑hoc cutting or cleaning methods
  • • Poor coordination between bricklayers, scaffolders and other trades leading to overloading of scaffolds with bricks and blocks or unsafe access to external leaf walls
  • • Failure to enforce exclusion zones around areas where bricks and blocks are being loaded, stacked, split or transported, increasing risk of crush or struck‑by injuries
  • • Inadequate oversight of apprentices and inexperienced labourers during higher risk activities such as core filling, masonry dressing and joint raking at height
  • • Lack of monitoring of brick saw and masonry cleaning operations, leading to uncontrolled dust, slurry and chemical exposure on shared work fronts
  • • Supervisors not trained to recognise early signs of wall instability, improper wall tie fixing or incorrect damp course placement
7. Material Handling, Storage and Logistics Systems
  • • Systemic failure to control how bricks, blocks and Hebel units are received, stacked and stored, leading to recurrent crush injuries from toppled stacks
  • • Lack of standardised limits for stack heights, configuration and proximity to edges, traffic routes and excavations
  • • Inadequate systems governing use of mechanical handling equipment (forklifts, telehandlers, cranes) for lifting pallets and cages of bricks and blocks
  • • Absence of documented traffic management plans integrating delivery vehicles, mobile plant and pedestrian bricklaying crews
  • • Over‑reliance on manual handling for transporting bricks and mortar due to poor planning for mechanical aids
  • • No procedure to manage partial pallets and loose bricks which are more prone to instability and spillage
  • • Poor housekeeping systems leading to scattered bricks, offcuts and broken blocks in access ways, increasing slip, trip and knock‑down hazards
8. Plant, Equipment and Maintenance Management
  • • Lack of systematic inspection and maintenance of brick saws, including guards, water suppression systems and electrical safety, leading to increased injury and silica exposure risks
  • • Absence of scheduled maintenance for mechanical handling equipment used in brick and block transport, resulting in failures under load
  • • Inadequate inspection and retirement criteria for brick grips, clamps, slings and lifting attachments, leading to use of damaged or unsuitable equipment
  • • Poor management of hand tools used for block splitting, dressing, joint raking and cutting, increasing risk of hand and eye injuries
  • • No system to verify that safety features such as emergency stops and lock‑out devices on saws and hoists are functional
  • • Uncontrolled modification or makeshift repairs to equipment used with masonry units, compromising design safety
9. Health Risk Management (Silica, Chemicals, Noise and Ergonomics)
  • • Chronic exposure to respirable crystalline silica from brick and block cutting, Hebel dressing, joint raking and masonry cleaning without adequate system controls
  • • Use of masonry cleaning chemicals and acids without robust controls, resulting in inhalation of fumes, skin and eye burns and environmental contamination
  • • Excessive noise exposure from brick saws and associated plant where no noise management plan is in place
  • • Poorly designed manual handling systems leading to musculoskeletal disorders from repetitive handling of bricks, blocks, Hebel panels and mortar
  • • Inadequate provision and management of personal protective equipment such as RPE, eye protection, gloves and hearing protection
  • • Lack of health monitoring programs where required for workers significantly exposed to silica or hazardous chemicals
10. Working at Heights, Scaffolding and Structural Stability Systems
  • • Systemic failure to ensure adequate and compliant work platforms and edge protection for upper level brick and block laying and face brickwork tasks
  • • Poor control over loading of scaffolds and temporary platforms with bricks, blocks and mortar, leading to structural failure or collapse
  • • Inadequate temporary bracing and tie‑in systems for partially built external leaf walls and Hebel panels, resulting in wall collapse
  • • Lack of standard procedures for installing wall ties and damp course in a way that maintains structural integrity during construction
  • • Inadequate coordination with scaffolders regarding placement of brick stacks, movement of materials and alteration of scaffold components
  • • Failure to integrate joint raking, brick cleaning and other follow‑on tasks into the overall heights management system, leading to unsafe access improvisations
11. Incident Reporting, Investigation and Corrective Action
  • • Under‑reporting of incidents, near misses and hazards related to brick and block laying, including toppled stacks, dropped masonry units and equipment failures
  • • Lack of structured incident investigation processes, leading to repeated systemic issues such as unstable stacking or incorrect use of brick grips
  • • Failure to identify root causes relating to management systems, focusing only on worker behaviour
  • • Inadequate tracking and close‑out of corrective actions arising from incidents, audits and inspections
  • • Poor communication of lessons learned across different projects and bricklaying crews
12. Monitoring, Audit and Continuous Improvement
  • • Absence of systematic monitoring of WHS performance for brick and block laying activities
  • • Reliance on informal observations rather than structured inspections and audits
  • • No clear performance indicators for key system risks such as crush injuries from toppled stacks, silica controls, or equipment maintenance compliance
  • • Failure to involve workers and subcontractors in reviewing the effectiveness of WHS systems and controls
  • • Inadequate management review of WHS performance leading to outdated controls and stagnation of safety improvements

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 – Construction Work: Guidance on managing WHS risks in construction, including masonry and structural work.
  • Model Code of Practice – How to Manage Work Health and Safety Risks: Framework for systematic hazard identification, risk assessment and control.
  • Model Code of Practice – Managing the Risk of Falls at Workplaces: Requirements for working at heights and scaffolding relevant to brick and block laying.
  • Model Code of Practice – Managing Noise and Preventing Hearing Loss at Work: Guidance on controlling noise from brick saws, mixers and associated plant.
  • Model Code of Practice – Managing the Risks of Respirable Crystalline Silica from Engineered Stone in the Workplace: Referenced for silica risk principles applicable to masonry cutting and chasing.
  • AS/NZS ISO 31000:2018: Risk management — Guidelines
  • AS/NZS 4801 / ISO 45001: Occupational health and safety management systems — Requirements for systematic WHS governance.
  • AS/NZS 1576 & AS/NZS 4576: Scaffolding — Requirements and guidelines for safe scaffold design, erection, use and maintenance.
  • AS 2550 series: Cranes, hoists and winches — Safe use for materials handling and lifting associated with masonry works.
  • AS/NZS 3012: Electrical installations — Construction and demolition sites, for electrical safety of plant used in brick and block laying.
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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