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Manual handling and blocklayers and stonemasons

Manual handling injuries result in significant numbers of lost time injuries to blocklayers and stonemasons. This document provides practical examples of how all stakeholders in the Building and Construction Industry can assist in reducing the risk of manual handling injury to blocklayers and stonemasons.

Contents

  1. Introduction
  2. Legal obligations
  3. Designers and manufacturers
  4. Principal contractor
  5. Blocklayers, stonemasons and labourers
  6. Further information

1. Introduction

Blocklayers and stonemasons are at a higher risk than most workers of sustaining a manual handling injury. Manual handling injuries are the largest single cause of injury resulting in blocklayers and stonemasons having to take time off work. As well as costing millions of dollars per annum these injuries result in pain and suffering to the injured worker and their families and a loss of experience, skills and productivity to the industry.

Manual handling injuries are caused by more than just lifting. Manual handling involves any activity requiring the use of force exerted by a person to lift, lower, push, pull, carry or otherwise move, hold or restrain a person, animal or thing. Common manual handling activities that result in injuries among blocklayers and stonemasons include: moving blocks/stones around site, a single person manually laying a large number of blocks/stones in excess of approximately 20kg and laying blocks/stones in awkward positions.

Manual handling problems need to be addressed systematically through the three-step process of:

  • Hazard identification (hazard means anything that may result in injury or harm to health);
  • Risk assessment (this involves looking at the possibility of injury or harm occurring to a person if exposed to a hazard. A number of manual handling risk factors, for example the weight of an object and the workers? posture, need to be considered in this step); and
  • Risk control (this involves introducing measures to eliminate or reduce the risk of a person being injured or harmed. The order in which controls should be considered is elimination, substitution, isolation, engineering control, administration control, and personal protective equipment; note - more than one control can be used at one time to reduce the exposure to a manual handling hazard).


To get the best result everyone should be involved in the process. The Manual Handling Code of Practice contains more detail on the manual handling risk management process and training requirements.

2. Legal obligations

The Occupational Safety and Health Act contains general duties, which describe the responsibilities of people who affect safety and health at work. Employers, employees, self employed persons, persons who have control of workplaces, designers, manufacturers, importers and suppliers of plant and hazardous substances and designers and constructors of buildings or structures all have Duties of Care they must fulfil to comply with the legal requirements of the Act.

Regulation 3.4 of the Occupational Safety and Health Regulations specifically details the requirement to manage manual handling hazards in the workplace. The regulation outlines the three-step risk management process of hazard identification, risk assessment and risk control.

3. Designers and manufacturers

Designers

Risks from manual handling can be avoided or minimised during the design stage. The Duty of Care of Designers outlined in the Occupational Safety and Health Act places a legal obligation on Designers to ensure the design of the building or structure does not expose persons properly constructing, maintaining, repairing or servicing the building or structure to hazards. Designers therefore must consider the manual handling risks to blocklayers and stonemasons, which may arise from their designs and plan to reduce or eliminate the risks. Examples include:

  • specify the lightest weight product that meets the design criteria. Blocks between approximately 6kg-20kg are considered acceptable to be laid by a single person using 2 hands. The weight of blocks for large building projects where it is likely the blocks will be laid by a single person should be kept under 20kg;
  • consider if the walls can be prefabricated into panels so the blocks/stones are laid at ground level and the finished panels erected;
  • plan and design safe access for construction and future maintenance. Ensure there is enough space for access with mechanical handling equipment, eg if large blocks are being used to build a retaining wall ensure there is adequate access for a mechanical lifting device to lift and place the blocks;
  • ensure specifications and plans are clearly marked with the weights of the materials; and
  • design, specify and mark lifting points into large building components.

Manufacturers and Suppliers

Manufacturers and suppliers of blocks can assist in reducing manual handling risks to blocklayers and stonemasons. Examples include:

  • regard how the block is going to be laid and consider the weight of the products accordingly. If a single person is going to be manually laying the product then the weight of the product should not exceed 20kg;
  • reduce the weight of bagged products, eg reduce the size of cement bags from 40kg to 20kg;
  • package the blocks so they can be moved safely around the site. Where the blocks are to be loaded onto a scaffold ensure the safe load capacity of the scaffold is not exceeded. Additionally block packs should be a manageable size to move around the scaffold;
  • clearly mark the load to indicate the weight of products, for example, note the weight of the block packs on the invoice;
  • use mechanical handling equipment, such as a crane or hiab, when delivering equipment and/or supplies. The point of delivery should be as close to the point of use as possible; and
  • include purpose designed, reinforced lifting points clearly marked on the load, to provide for the safe use of cranes, hiabs or other mechanical lifting equipment.

4. Principal contractor

Planning and coordination phase

The Occupational Safety and Health Act sets out a Duty of Care for the Principal Contractor. This Duty of Care requires safe systems of work to be established and maintained and be supported by adequate information, instruction, training and supervision. Correct planning can make sure safe systems of work are established and adequate information, instruction, training and supervision is provided. Good planning will avoid or reduce many of the manual handling hazards associated with block and stone laying and will benefit the productivity of the job as well as promote safety. The following guidelines provide some practical ideas.

Access/egress

At the beginning of the job, it is essential to establish a clear access/egress way to allow for the safe movement of materials and equipment around the site, for example put limestone driveways in during the site preparation stage. As a minimum adequate access/egress ways must be established by using planks or other suitable alternatives.

Consideration needs to be given to access/egress for building retaining walls etc, that that are difficult to get to for example when large blocks or stones need to be moved to the rear of an existing house with no rear access. Special handling equipment may need to be considered or the size of the blocks or stones may need to be modified.

Scaffold

When the blocks are to be laid from a scaffold ensure the safe load capacity of the scaffold is not exceeded. Generally a heavy-duty scaffold must be used to make sure the load is within the capacity of the scaffold. A loading bay should be located appropriately, giving consideration to access/egress. The movement of the blocks, equipment and people around the scaffold needs to be considered with particular attention to establishing and maintaining an even, stable and secure working platform, i.e. make sure the scaffold planks are even and secured.

Works programming

The programme of works should take into consideration the implications to blocklayers and stonemasons constructing retaining walls etc.

  • Sequence work to prevent ?rush jobs? as far as practicable;
  • Coordinate the trades to allow the blocklayer or stonemason to complete work free from obstruction; and
  • Allow for the progressive clean up of the work area to prevent debris/rubbish becoming a trip hazard.

Materials delivery/storage

Material delivery and storage areas should have enough space and lighting to allow for the safe movement of the materials. The ground conditions of storage and lay down areas should be even and compacted. Examples of safe work practices include:

  • Ensure the blocks, stones and other materials are delivered as close as possible to the job, eg the site supervisor can fax the site plans specifying delivery points to the delivery company with the order;
  • Wherever possible ensure mechanical aids are used to move large, heavy loads;
  • Have adequate storage space and systems in place to maintain blocks etc so there is minimal double handling; and
  • Ensure the work area is flat/ level ground where practicable. On a building site using blocks for the walls make sure the slab area has a flat, compacted graded area around it to accommodate the block pallets.

Selection of material

Selecting materials that are lighter and easier to handle decreases the overall workload of the blocklayer and stonemason. Examples include:

  • Use the lightest products possible. It is important to keep blocks that are to be laid by a single person under approximately 20kg.
  • Provide 20kg bags of cement instead of 40kg bags of cement, or consider bulk cement alternatives, if appropriate.

Provision of mechanical lifting and handling equipment

Mechanical lifting and handling equipment must be considered to move heavy/awkward products, tools and equipment around the site. The provision and maintenance of the equipment should be planned at the beginning of the job. Examples of equipment that may need to be considered and directly or indirectly budgeted for includes:

  • the use of a crane or other mechanical lifting device to lift and place large lintels. A telehandler or hand-operated lift truck are other examples of mechanical lifting devices that can be utilised to place lintels;
  • the use of a crane or other mechanical lifting device to move blocks up onto the first storey slab or scaffold;
  • wheelbarrows specifically designed to move heavy loads such as a two wheeled barrow or a motorised barrow;
  • pallet lifter or other suitable mechanical lifting device to move packs of blocks or stone around site;
  • the use of hiabs, winches or ramps to load and unload work vehicles;
  • wheeled block cutters; and
  • when digging trenches for retaining walls provide mechanical digging devices suitable for the task whenever practicable, such as a bobcat or backhoe. In addition ensure all excavation work is carried out in accordance with the requirements detailed in the Excavation Code of Practice. If it is necessary to dig manually using a shovel ensure the most appropriate shovel for the job is available, examples include:
    • shovels with shock absorbing handles when digging around tree roots, rubble etc; and
    • have both long and short handle shovels available to suit the task/person.

Selection of tools and equipment

When selecting tools and equipment the safety of the operator must be considered. There should be consultation with the blocklayer or stonemason to identify the most appropriate tool/equipment. Consideration needs to be given to factors such as the weight and vibration of the tools/equipment and to the work environment in which it will be used.

Team lifting

Team lifting can be utilised for one-off lifts of tools and equipment however team lifting has inherent risks and does not provide a long-term solution for moving heavy materials. The heavier the materials the higher the risk of manual handling injury when team lifting. Team lifting is often neither time nor cost effective. Alternatives to team lifting should be considered during the planning phase. If team lifting is utilised all workers involved must be trained and the lift coordinated.

Construction phase

During the construction phase the Principal Contractor has a legal responsibility to ensure the maintenance of site safety. Safety and health policies, procedures and safe systems of work should be established at the beginning of a project, be continuously monitored and regularly reviewed throughout the job. Site inductions, appropriate training, and ongoing supervision are required throughout the construction phase to ensure safe systems are achieved and maintained.

Access/egress

The ongoing maintenance of clear routes to and from work areas to enable the safe movement of materials, equipment and people around site is essential. Adequate rubbish receptacles need to be provided and maintained in dedicated areas. Material hoists should not be removed before all materials have been put in place.

Work layout

Working platform planks must be secured and maintained. Where practicable the working platform should allow the blocklayer and stonemason to complete their work in a good posture, i.e. between knee and shoulder height.

Cutting equipment should be at approximately hip-waist height so that work is completed at an optimal working height.

Good housekeeping

Good housekeeping on a site has many positive effects including increased harmony between different sub contractors, decreased probability of accidents and increased productivity. The site supervisor should ensure the work areas are free of obstructions that may prevent the safe movement of materials and people.

5. Blocklayers, stonemasons and labourers

All blocklayers, stonemasons and their labourers have a legal responsibility, to ensure their own safety and health at work and to avoid adversely affecting the safety and health of any other person. Some practical examples for block layers and stonemasons are outlined below.

Safe work practices - general

Developing and maintaining safe work practices reduces the risk of injury. Specific examples for blocklayers, stonemasons and their labourers include:

  • The physical workload of blocklayers and stonemasons is significantly affected by the posture of the blocklayer or stonemason. Examples of work practices to reduce the time spent stooping or over stretching are:
    • Maximise the time spent laying blocks or stones between knee and shoulder height by altering the height of the working platform when working from a scaffold whenever this is practicable;
    • Raise the mortarboard to reduce the time spent in a stooped posture;
    • Always complete cutting work etc at approximately hip height;
  • Use 2 hands to lift and place blocks. DO NOT use the trowel as a lifting tool;
  • If working from a scaffold ensure it has an adequate load capacity and there is adequate workspace and access/egress to safely move the blocks/stones;
  • To avoid injury to muscles, ligaments and other soft tissues do warm-up/stretching exercises at the beginning of the day and cool down/stretching exercises at the end of the workday. This is what athletes do to reduce the risk of soft tissue injury;
  • Use mechanical lifting and handling equipment when and as required (see above for examples of the equipment);
  • Always use the lightest possible tool for the job;
  • Do not manually lift or move anything if there is any uncertainty that it can be done safely; and
  • Always seek assistance if necessary.

Safe work practices - loading and unloading work vehicles

Heavy equipment has to be loaded and unloaded, often several times per day. Loads can be heavy, awkward and difficult to access. To minimise manual handling consider the following:

  • Use mechanical assistance such as a hiab;
  • Modify the tailgate so it is mechanically lifted and lowered;
  • Have removable tailgate and sides;
  • Use the lightest weight tools and equipment practical for the job; and
  • Install ladder rollers on the roof rack to assist with taking ladders on/off the vehicle;

 Safe work practices - moving blocks, stones and mortar

Blocks, stones and mortar need to be moved around site. The loads can be very heavy and in some cases awkward to move. Some solutions include:

  • Never move wheelbarrows, trolleys and/or pallet lifters through sand or over uneven terrain and always make sure the there is a clear access/egress. As a minimum there must be planks or other suitable alternatives in place;
  • Never hand ball blocks or stone;
  • Always use wheelbarrows or trolleys designed for moving heavy loads such as mortar, for example a two-wheeled wheelbarrow or a wide wheeled barrow. Consideration should be given to a motorised barrow, which can be utilised as a wheelbarrow and a block trolley; and
  • If the blocks are an unstable load report it to your site supervisor to feedback to the manufacturer.

Safe work practices - mixing mortar

Strategies to minimise the physical workload associated with shovelling sand and moving bags of cement include:

  • Always use a trolley/wheelbarrow to move bags of cement rather than carrying them;
  • Never try to carry multiple bags of cement at one time;
  • Use both long and short handled shovels that best suit the task/person, eg use a long handled shovel if there is a large reach involved; and
  • Take regular breaks from continuous shovelling. When possible break up continuous shovelling with alternative tasks.

Safe work practices - digging

A number of injuries are associated with digging. Problems include using inappropriate tools, hitting an unexpected object and having to get into awkward positions. Before digging commences always identify the location of all the services. All excavation work should be carried out in accordance with the Excavation Code of Practice. Examples of solutions include:

  • Use excavator/bobcat or other mechanical digging device whenever possible;
  • If using hand held shovels
    • Use shovels with shock absorbing handles when digging near tree roots, brick rubble etc; and
    • Use both long and short handled to suit task/person, eg use "extra short" handle shovels when digging in a confined trench area.
  • Make sure adequate training has been received for the digging to be done in the safest possible way.

Good housekeeping

All workers involved in all trades on site have a responsibility for maintaining site tidiness. Routine, regular cleanups should be scheduled as part of the workday. Working on a tidy, well-maintained site makes the job easier and safer.

Team Lifting

Training must be provided for all blocklayers, stonemasons and labourers involved in team lifting. The lift needs to be coordinated by a "leader". Remember team lifting should not be considered an adequate long-term control. Team lifting in inherently dangerous and alternative solutions should be considered.

6. Further information

For further information contact WorkSafe on 1300 307 877. 

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