Too much to handle? Tips for preventing injuries in the workplace

1 October 2019

John Southall, Managing Director of Health and Safety Consultancy Southalls, the company that provides the BMF Safety Plus service, explains how to minimise injury when handling bricks and blocks

John SouthallLifting and handling bricks and blocks is a highly repetitive task. It can also involve twisting, stooping or reaching upwards. The risk of injury increases with the weight of the block. Workers are particularly at risk if they are repetitively handling blocks heavier than 20 kg.

Injuries from handling heavy concrete and stone block products do not usually occur because of a ‘one-off’ lift. The injuries usually arise from the ongoing repetition of the work and posture during the lifting. These factors can create excessive stresses and strains on the body, which can cause damage to muscles and tendons. Many of these injuries could be prevented if staff followed correct manual handling techniques.

The Manual Handling Operations Regulations 1992 require every employer to avoid hazardous manual handling as far as practicable. Where unavoidable, employers must assess and reduce the risk from manual handling operations at work.

Top Tips to Reduce the Risk of Manual Handling Injury


1. Avoid. It is common sense, but always avoid handling bricks and blocks as much as you can. Usually stored on pallets or banded and shrink-wrapped, the first choice for handling should be by a lift truck or lorry brick grab.

2. Use handling aids. Where small loads need moving around the site, use a trolley rather than carrying. Trolleys should be pushed rather than pulled.

3. Plan the lifting/handling.  Are any obstructions in the way? Check walkways are clear of obstructions, trip and slip hazards prior to lifting. Where manual handling is unavoidable, ensure there is sufficient access around the brick or block stack, to keep bricks or blocks close to the body and avoid unnecessary overreaching and stretching.

4. Adopt a good lifting position, with a firm hold and upright posture. Keep the load close to the body and avoid twisting or leaning sideways or jerking the load. Provide staff with training in correct manual handling techniques. Southalls’ Safety Cloud – part of the BMF Safety Plus service - offers ‘manual handling for builders merchants’ via e-learning.

5. Don’t lift or handle more than can be easily managed.
There is a difference between what people can lift and what they can safely lift.

6. Positioning. If the load needs to go into a precise position, put it down first, then slide into position.

7. PPE. Steel toe-capped boots or gloves may be needed but clothing should not restrict or impede movement. Consider wearing appropriate gloves when handling blocks and bricks to protect against cuts and abrasions from sharp edges.

8. Storage height Try to store heavier items at elbow height rather than below knee height or above shoulder height to reduce strain on the spine.

9. Repetitive Lifting and rest breaks. Prolonged poor technique when lifting even lightweight items them can lead to severe and lasting injury. If you are re-stacking a collapsed pile of bricks, ensure you take adequate breaks.

Safe Storage
The stability of stacked bricks and blocks depends upon the condition of the pallets on which blocks are stored and the quality of the banding/shrink-wrapping of packs of bricks. Ideally, stacks should be no more than 4 packs high, where pallets, banding and shrink-wrapping is in good condition.

Any stacked packs near perimeter fences should not exceed the height of the fence line, with the next stacks increasing gradually in height in a staggered manner, to prevent any potential of packs falling outside of the curtilage of the premises. Often customers rip shrink wrapping or cut banding to access individual bricks from ‘server’ packs. This results in split, unstable packs, prone to collapse. These packs should be monitored and loosely shrink-wrapped, to prevent uncontrolled falling bricks. Brick bins are a great solution to this - used to store loose bricks that customers can pick from, so there is no need for them to open and pick from a stored pack.

Southalls specialise in helping builders merchants stay on top of their health and safety legal requirements, keeping their staff and customers safe, and their businesses compliant. For information about the BMF Safety Plus service or to discuss any health and safety matter, please get in touch with the Southalls team on 0345 257 4015 or [email protected].

BMF members can also request the following BMF H & S Business Guide on Material Storage and Handling from [email protected]


This article first appeared in the September 2019 edition of Builders Merchants Journal (BMJ)