Product Overview

Summary: This Stone Masonry Safe Operating Procedure sets out a clear, safe and consistent method for cutting, shaping, lifting and installing stone in Australian workplaces. It helps masonry businesses control high‑risk tasks such as silica dust exposure, manual handling of heavy stone and working at height, while supporting strong WHS compliance and quality workmanship on every project.

Stone masonry work combines precision craftsmanship with high‑risk physical tasks, from cutting and grinding engineered and natural stone through to lifting heavy slabs and fixing them in position on site. Without a structured procedure, businesses can face serious incidents involving silica dust exposure, crush injuries, falls from height and hand and arm injuries from power tools. This Stone Masonry Safe Operating Procedure provides a practical, step‑by‑step framework that integrates safety, quality, and productivity into one consistent way of working across workshops, fabrication facilities and construction sites.

Developed for the Australian WHS environment, this SOP guides workers and supervisors through planning the job, selecting and inspecting equipment, controlling dust and noise, managing hazardous manual tasks, and implementing safe systems of work when operating saws, grinders, polishers and lifting gear. It supports PCBUs in demonstrating due diligence under WHS legislation, simplifies onboarding of new staff and apprentices, and reduces the risk of rework and costly downtime caused by poor preparation or unsafe methods. The result is a defensible, easy‑to‑follow procedure that helps your team deliver high‑quality stonework while protecting people, reputation and project timelines.

Key Benefits

• Ensure compliance with Australian WHS laws and guidance relating to stone, silica dust and high‑risk construction work.
• Reduce the likelihood of serious injuries from manual handling, cutting equipment, lifting operations and working at heights.
• Standardise stone masonry work methods across workshop and site teams, improving consistency, quality and productivity.
• Streamline induction and training for new stonemasons and apprentices with clear, task‑based instructions and safety controls.
• Demonstrate a documented, defensible approach to risk management during regulator inspections, client audits or incident investigations.

Who is this for?

• Stonemasons
• Apprentice Stonemasons
• Construction Site Supervisors
• WHS Managers
• Construction Project Managers
• Residential and Commercial Builders
• Landscaping Contractors
• Workshop Managers
• Health and Safety Representatives (HSRs)

Hazards Addressed

• Respirable crystalline silica (RCS) exposure from cutting, grinding and polishing stone
• Manual handling injuries from lifting, carrying and positioning heavy stone slabs and blocks
• Crush and pinch injuries from slab handling frames, clamps, trolleys and mechanical lifting equipment
• Cuts, lacerations and amputations from stone saws, grinders and other powered hand tools
• Flying particles and chips from cutting, chiselling and dressing stone
• Noise‑induced hearing loss from powered cutting and grinding equipment
• Trips, slips and falls due to wet, uneven or cluttered work surfaces and off‑cuts
• Falls from height when installing stone on scaffolds, elevated work platforms or stairways
• Electrical hazards from power tools, extension leads and water‑cooled cutting systems
• Fatigue and musculoskeletal disorders from repetitive tasks and awkward postures

Included Sections

• 1.0 Purpose and Scope
• 2.0 References and Applicable Legislation
• 3.0 Definitions (Stone Types, RCS, High‑Risk Construction Work, etc.)
• 4.0 Roles and Responsibilities (PCBUs, Supervisors, Stonemasons, Apprentices)
• 5.0 Planning and Job Preparation for Stone Masonry Tasks
• 6.0 Hazard Identification and Risk Assessment for Stone Masonry Work
• 7.0 Required Competencies, Licences and Training
• 8.0 Tools, Plant and Equipment (Saws, Grinders, Polishers, Lifting Gear)
• 9.0 Personal Protective Equipment (PPE) Requirements
• 10.0 Dust Control Measures (Wet Cutting, Local Exhaust Ventilation, Housekeeping)
• 11.0 Safe Use of Stone Cutting and Grinding Equipment
• 12.0 Manual Handling and Mechanical Lifting of Stone Slabs and Blocks
• 13.0 Safe Work at Heights When Installing Stone
• 14.0 Noise Management and Vibration Control
• 15.0 Workshop and Site Housekeeping, Waste and Slurry Management
• 16.0 Inspection, Maintenance and Pre‑Use Checks for Equipment
• 17.0 Emergency Procedures (Injuries, Equipment Failure, Silica Exposure Incidents)
• 18.0 Health Monitoring and Exposure Management for Silica
• 19.0 Documentation, Recordkeeping and Review of the SOP

Legislation & References

• Work Health and Safety Act 2011 (Cth) and equivalent state and territory WHS Acts
• Work Health and Safety Regulation 2011 (Cth) and equivalent state and territory WHS Regulations
• Safe Work Australia – Model Code of Practice: Managing the Risks of Respirable Crystalline Silica from Engineered Stone in the Workplace
• Safe Work Australia – Model Code of Practice: Managing Risks of Hazardous Chemicals in the Workplace
• Safe Work Australia – Model Code of Practice: Hazardous Manual Tasks
• Safe Work Australia – Model Code of Practice: Managing Noise and Preventing Hearing Loss at Work
• Safe Work Australia – Model Code of Practice: Managing the Risk of Falls at Workplaces
• AS/NZS 1715: Selection, use and maintenance of respiratory protective equipment
• AS/NZS 1716: Respiratory protective devices
• AS/NZS 2161: Occupational protective gloves
• AS/NZS 1337.1: Personal eye protection
• AS/NZS 1801: Occupational protective helmets
• AS/NZS 1891.4: Industrial fall‑arrest systems and devices – Selection, use and maintenance
• AS 2550 series: Cranes, hoists and winches – Safe use (where mechanical lifting of stone is undertaken)