Product Overview

Summary: This Safe Operating Procedure sets out a safe, consistent method for applying sealant in masonry joints on Australian construction and maintenance sites. It helps control key WHS risks such as falls, chemical exposure and manual handling while improving the durability and weatherproofing of masonry structures.

Sealant application in masonry joints is a critical task for ensuring the long-term performance of walls, facades and structural elements, particularly in Australia’s harsh and variable climate. Poor technique, incorrect product selection or inadequate surface preparation can lead to water ingress, cracking, premature sealant failure and costly rework. At the same time, workers are often operating at height, using powered tooling and handling chemical products that introduce significant WHS risks if not properly controlled.

This Safe Operating Procedure provides a clear, step-by-step framework covering planning, surface preparation, joint treatment, sealant application and post-application inspection, all through a WHS lens. It outlines mandatory PPE, safe use of access equipment, controls for exposure to sealant vapours and skin contact, and measures to prevent slips, trips and falls around wet work areas. By adopting this SOP, businesses can standardise work quality across crews, demonstrate compliance with Australian WHS legislation and relevant standards, and significantly reduce the likelihood of leaks, defects, injuries and disputes with clients.

Designed for construction, refurbishment and maintenance environments, this document supports both new builds and remedial works on masonry structures. It helps organisations integrate safety into everyday site activities, align with principal contractor requirements, and provide defensible evidence of due diligence in the event of an incident or audit.

Key Benefits

• Ensure consistent, high-quality sealant application that improves masonry durability and weatherproofing.
• Reduce WHS risks associated with working at height, chemical exposure and manual handling during sealant works.
• Demonstrate compliance with Australian WHS legislation, site safety management plans and client requirements.
• Streamline training and competency development for new and existing workers performing sealant application.
• Minimise rework, defects and warranty claims arising from failed or poorly installed masonry joint sealants.

Who is this for?

• Bricklayers
• Stonemasons
• General Construction Workers
• Waterproofing Technicians
• Site Supervisors
• Construction Project Managers
• WHS Advisors and Safety Officers
• Facilities and Maintenance Managers

Hazards Addressed

• Falls from height when accessing elevated masonry joints (scaffolds, ladders, EWP).
• Skin and eye irritation or burns from contact with sealants, primers and cleaning solvents.
• Inhalation of vapours, fumes or dust from sealants, primers and joint preparation activities.
• Hand and finger injuries from cutting out old sealant, tooling joints and using sharp blades.
• Musculoskeletal disorders from repetitive movements, awkward postures and manual handling of sealant cartridges and equipment.
• Slips, trips and falls due to hoses, cords, offcuts and spilled materials in the work area.
• Environmental contamination from improper disposal of waste sealant, cartridges and solvent containers.

Included Sections

• 1.0 Purpose and Scope
• 2.0 References, Definitions and Abbreviations
• 3.0 Roles and Responsibilities
• 4.0 Required Competencies, Licences and Training
• 5.0 Tools, Equipment and Materials
• 6.0 Personal Protective Equipment (PPE) Requirements
• 7.0 Hazard Identification and Risk Controls for Sealant Application
• 8.0 Pre-Start Checks and Site Preparation
• 9.0 Surface Preparation and Joint Cleaning Procedure
• 10.0 Product Selection, Storage and Handling Requirements
• 11.0 Step-by-Step Sealant Application Procedure
• 12.0 Working at Height and Access Equipment Controls
• 13.0 Ventilation and Control of Vapours and Fumes
• 14.0 Quality Control, Inspection and Acceptance Criteria
• 15.0 Waste Management and Environmental Protection
• 16.0 Emergency Procedures (Exposure, Spills, Falls)
• 17.0 Documentation, Records and Review

Legislation & References

• Work Health and Safety Act 2011 (Cth) and harmonised state and territory WHS Acts
• Work Health and Safety Regulations 2011 (Cth) and equivalent state and territory regulations
• Safe Work Australia – Code of Practice: Managing the Work Environment and Facilities
• Safe Work Australia – Code of Practice: Hazardous Manual Tasks
• Safe Work Australia – Code of Practice: Managing Risks of Falls at Workplaces
• AS/NZS 1891.4: Industrial fall-arrest systems and devices – Selection, use and maintenance
• AS 1657: Fixed platforms, walkways, stairways and ladders – Design, construction and installation
• AS/NZS 1715: Selection, use and maintenance of respiratory protective equipment
• AS/NZS 2161: Occupational protective gloves
• AS 3700: Masonry structures (for context on masonry construction and detailing)