Masonry Contractor Safety Manual

Silica Exposure in Masonry Work

Respirable crystalline silica is one of the most significant occupational health hazards associated with masonry construction.

Employees may be exposed to silica dust while:

• Cutting brick, block, concrete, tile, or stone
• Operating masonry saws
• Grinding masonry materials
• Tuckpointing
• Drilling
• Chipping or jackhammering
• Mixing silica-containing materials
• Cleaning dusty work areas
• Demolishing masonry
• Removing mortar
• Sweeping or handling accumulated dust

The company should maintain a written Silica Exposure Control Program when required and identify tasks that can expose employees to respirable crystalline silica.

Engineering and work-practice controls should be used as required, including appropriate water-delivery systems and dust collection equipment.

Employees should understand the silica hazards associated with their work and the controls required for each task.

Masonry Saws and Cutting Equipment

Masonry saws can expose employees to rotating blades, flying particles, silica dust, noise, electrical hazards, and kickback.

Before operating a masonry saw:

• Inspect the saw and blade.
• Verify that guards are installed and properly positioned.
• Use the correct blade for the material and equipment.
• Inspect blades for damage or excessive wear.
• Make sure the workpiece is stable.
• Keep hands away from the blade path.
• Use required eye, face, hearing, and respiratory protection.
• Use required silica dust controls.
• Follow the manufacturer’s operating instructions.

When water is used for silica control, electrical equipment and connections must be protected from water-related hazards.

Employees should never remove guards, force a blade through material, or use damaged equipment.

Grinding and Tuckpointing

Tuckpointing and mortar removal can generate substantial amounts of respirable crystalline silica.

Grinding equipment used for mortar removal should be operated with the required engineering controls, work practices, and respiratory protection.

Employees should:

• Inspect grinders before use.
• Use appropriate guards.
• Use the correct wheel or accessory.
• Maintain dust collection equipment.
• Position themselves to control kickback.
• Keep other employees away from the immediate work area.
• Wear appropriate eye and face protection.
• Wear hearing protection when required.
• Use respiratory protection when required.

Grinding wheels should be inspected before use and removed from service when damaged.

Written Silica Exposure Control Plan

When applicable, the contractor should maintain and implement a written exposure control plan addressing masonry tasks that expose employees to respirable crystalline silica.

The plan should identify:

• Tasks involving silica exposure
• Engineering controls
• Work-practice controls
• Required respiratory protection
• Housekeeping procedures
• Procedures for restricting access when necessary
• The competent person responsible for implementing the plan

The plan should reflect the actual tools and work methods used by the company.

Respiratory Protection

Respiratory protection may be required for certain masonry operations, including some cutting, grinding, tuckpointing, drilling, chipping, demolition, and cleanup activities.

When respirators are required, the company should maintain a Respiratory Protection Program addressing:

• Respirator selection
• Medical evaluations
• Fit testing
• Training
• Inspection
• Cleaning
• Storage
• Cartridge or filter replacement
• Program evaluation

Employees must not substitute an ordinary dust mask for required respiratory protection.

Masonry Wall Construction

Masonry walls under construction may be unstable until adequately supported by the permanent structure or temporary bracing.

Work should be planned to prevent walls from overturning or collapsing.

Employees should not work in areas where an unsupported masonry wall could fall unless their presence is necessary for construction of the wall and applicable protective requirements have been established.

Materials should not be stored or equipment operated in a manner that could overload or destabilize walls or supporting structures.

Limited Access Zones

A limited access zone should be established as required when masonry walls are being constructed.

The zone should:

• Be established before wall construction begins.
• Extend along the length of the wall.
• Be located on the unscaffolded side of the wall.
• Restrict access to employees actively engaged in constructing the wall.
• Remain in place until the wall is adequately supported as required.

Employees not involved in constructing the wall should remain outside the limited access zone.

Masonry Wall Bracing

Masonry walls must be adequately supported to prevent overturning or collapse.

Temporary bracing should be:

• Designed or selected for the wall being supported.
• Installed as work progresses when required.
• Maintained in effective condition.
• Protected from damage or unauthorized removal.
• Inspected when conditions could affect stability.
• Left in place until permanent supporting elements are installed.

Employees should not alter or remove wall bracing without authorization.

High winds, storms, impacts from equipment, changes in wall configuration, or other conditions that could affect stability should trigger reevaluation of the wall and its bracing.

Scaffolding Safety

Scaffolds are commonly used during masonry construction and may expose employees to falls, falling objects, scaffold collapse, electrical hazards, and overloading.

Scaffolds should be:

• Erected on adequate foundations.
• Properly supported and braced.
• Inspected before use.
• Provided with safe access.
• Protected against overloading.
• Kept clear of unnecessary materials and debris.
• Equipped with required fall protection.

Employees should not climb cross braces or use makeshift devices to gain additional working height.

Brick, block, mortar, tools, and other materials should be distributed to prevent scaffold overloading.

Fall Protection

Masonry contractors may perform work from scaffolds, aerial lifts, ladders, elevated floors, roofs, wall openings, and other elevated surfaces.

Fall hazards should be evaluated before work begins.

Depending on the work, protection may include:

• Guardrail systems
• Personal fall arrest systems
• Scaffold fall protection
• Covers
• Controlled access procedures where specifically permitted
• Safe ladder access
• Properly protected floor and wall openings

Employees should receive training on the fall hazards associated with their assigned work.

Falling Object Protection

Employees working below masonry operations may be exposed to falling brick, block, mortar, tools, and other materials.

Controls may include:

• Toe boards
• Screens
• Guardrails
• Barricades
• Debris containment
• Controlled access
• Tool and material storage practices
• Hard hats

Materials should not be stacked where they can fall from scaffolds, platforms, walls, or elevated surfaces.

Material Handling

Brick, block, stone, mortar, cement, scaffolding components, and masonry equipment can create significant lifting and material-handling hazards.

Employees should:

• Evaluate loads before lifting.
• Use proper lifting techniques.
• Avoid twisting while carrying heavy materials.
• Use team lifting when appropriate.
• Use mechanical equipment for heavy or repetitive loads when practical.
• Keep travel paths clear.
• Wear gloves appropriate for the material being handled.

Work should be organized to reduce unnecessary manual handling and repetitive lifting.

Forklifts, Telehandlers and Material Handling Equipment

Forklifts and rough-terrain telehandlers are frequently used to deliver masonry materials to elevated work areas.

Only trained and authorized employees should operate powered industrial trucks and other material-handling equipment.

Operators should:

• Inspect equipment before use.
• Follow rated-capacity limitations.
• Secure and stabilize loads.
• Maintain visibility.
• Control speed.
• Use seat belts when provided.
• Keep employees away from suspended or elevated loads.
• Maintain safe clearance from excavations, structures, scaffolds, and power lines.

Employees should never stand beneath elevated forks, platforms, pallets, or loads.

Cranes, Hoisting and Rigging

Masonry contractors may use cranes, hoists, forklifts, or other equipment to move brick, block, stone, mortar, scaffolding, and other materials.

Rigging should be selected based on the load and inspected before use.

Employees should:

• Stay clear of suspended loads.
• Never exceed equipment or rigging capacities.
• Use tag lines when appropriate.
• Protect rigging from sharp edges.
• Use qualified personnel when required.
• Maintain communication with equipment operators.

Damaged rigging should be removed from service.

Mortar, Cement and Chemical Exposure

Wet cement and mortar can cause skin irritation and serious chemical burns.

Employees should avoid prolonged or repeated skin contact and wear appropriate protective equipment.

Protection may include:

• Chemical-resistant or waterproof gloves
• Long sleeves
• Long pants
• Waterproof boots
• Eye and face protection

Contaminated clothing should be removed promptly, and affected skin should be washed with clean water.

Employees should not kneel in wet mortar or concrete without appropriate protection.

Hazard Communication

Employees may work with cement, mortar additives, cleaning chemicals, sealants, adhesives, coatings, fuels, and other hazardous products.

The Hazard Communication Program should address:

• Chemical inventory
• Container labeling
• Safety Data Sheets
• Employee training
• Non-routine tasks
• Chemical storage
• Protective measures

Employees should understand the hazards of the products they use and know how to obtain applicable Safety Data Sheets.

Personal Protective Equipment

PPE requirements should be based on the hazards associated with each task.

Common masonry PPE may include:

• Hard hats
• Safety glasses
• Goggles
• Face shields
• Work gloves
• Chemical-resistant gloves
• High-visibility apparel
• Safety-toe footwear
• Hearing protection
• Respiratory protection
• Fall protection equipment

Employees should inspect PPE before use and replace damaged or defective equipment.

Hearing Conservation

Masonry saws, grinders, rotary hammers, chipping tools, jackhammers, and other equipment may expose employees to hazardous noise.

The company should evaluate noise exposures and implement hearing conservation requirements when applicable.

Controls may include:

• Quieter equipment
• Equipment maintenance
• Increased distance from noise sources
• Limiting exposure duration
• Hearing protection

Employees should be trained in the proper use and care of required hearing protection.

Hand and Power Tool Safety

Masonry contractors commonly use:

• Grinders
• Drills
• Rotary hammers
• Chipping hammers
• Masonry saws
• Cutoff saws
• Mixers
• Trowels
• Hammers
• Chisels
• Power-actuated tools

Tools should be inspected before use and operated according to manufacturer instructions.

Guards and other safety devices should not be removed or defeated.

Damaged tools should be removed from service.

Electrical Safety

Temporary electrical systems, extension cords, portable tools, generators, and wet work environments may create electrical hazards.

Employees should inspect electrical equipment before use and protect cords from damage.

Ground-fault circuit interrupter protection should be provided as required.

Electrical equipment should not be used in standing water or other conditions for which it is not designed.

Ladder and Stairway Safety

Ladders may be used for short-duration access and work when appropriate.

Employees should:

• Inspect ladders before use.
• Select the correct ladder.
• Place ladders on stable surfaces.
• Maintain three points of contact while climbing.
• Avoid overreaching.
• Keep ladders away from electrical hazards.
• Follow manufacturer load ratings.

Damaged ladders should be removed from service.

Aerial Lifts and Scissor Lifts

Masonry contractors may use boom lifts or scissor lifts for elevated work, inspection, restoration, and access.

Only trained and authorized employees should operate this equipment.

Employees should follow manufacturer requirements for:

• Pre-use inspections
• Fall protection
• Platform capacity
• Travel
• Positioning
• Ground conditions
• Overhead hazards
• Electrical clearances

Employees should not climb or stand on platform guardrails to gain additional height.

Heat Stress

Masonry work is physically demanding and frequently performed outdoors.

Employees may be exposed to high temperatures while lifting materials, working from scaffolds, wearing PPE, or performing strenuous tasks.

Heat illness prevention should address:

• Drinking water
• Rest breaks
• Shade
• Acclimatization
• Work scheduling
• Recognition of heat illness
• Emergency response

Supervisors and employees should monitor changing weather and work conditions.

Housekeeping

Good housekeeping helps prevent slips, trips, falls, fire hazards, and unnecessary silica exposure.

Work areas should be kept free of:

• Broken masonry
• Scrap material
• Excess mortar
• Packaging
• Cords and hoses
• Unnecessary tools
• Other debris

Silica-containing dust should be cleaned using methods that minimize airborne exposure.

Materials should be stacked securely and should not obstruct walkways, scaffold access, ladders, stairs, or emergency routes.

Job Safety Analysis

A Job Safety Analysis (JSA) can help masonry contractors identify hazards and required controls before work begins.

JSAs may be appropriate for:

• Brick and block installation
• Masonry wall construction
• Masonry wall bracing
• Masonry saw operation
• Cutting brick or block
• Tuckpointing
• Grinding
• Drilling
• Chipping and demolition
• Scaffold erection and use
• Material hoisting
• Telehandler operations
• Stone installation
• Aerial lift work
• Work near overhead power lines

The JSA should identify the steps of the task, associated hazards, and controls necessary to perform the work safely.

Masonry Safety Training

Employees should receive training appropriate to their assigned work and exposures.

Training may include:

• Silica exposure control
• Masonry saw safety
• Grinder and tuckpointing safety
• Respiratory protection
• Scaffold safety
• Fall protection
• Limited access zones
• Wall bracing
• PPE
• Material handling
• Forklift and telehandler safety
• Rigging
• Hazard communication
• Hearing conservation
• Heat stress
• Electrical safety
• Emergency procedures

Training should be documented and updated when work practices, equipment, materials, hazards, or regulatory requirements change.

Building a Masonry Contractor Safety Manual

A Masonry Contractor Safety Manual should be customized to the contractor’s actual work rather than relying on a generic construction safety manual.

A residential brick and block contractor may require a different combination of programs than a commercial masonry contractor performing multi-story structural masonry, restoration, stone installation, tuckpointing, or large-scale scaffold work.

The completed manual should address the hazards employees actually encounter and provide practical procedures that supervisors and employees can use in the field.

When properly developed, the safety manual supports employee training, OSHA compliance, hazard assessments, JSAs, inspections, incident investigations, project safety requirements, and the contractor’s overall safety-management system.