Tuck Pointing & Repointing SWMS

Tuck pointing and repointing involves raking out deteriorated mortar joints from masonry walls, chimneys and parapets, then refilling with fresh mortar and applying a fine lime putty fillet to create a decorative line. The work is typically performed at height on scaffolds, elevating work platforms or ladders, often on heritage buildings where substrates are fragile and access is constrained. The task combines mechanical raking with angle grinders, chisels or oscillating tools, prolonged awkward postures with arms overhead, and continuous handling of cementitious materials. It generates significant respirable crystalline silica (RCS) dust from mortar, brick and stone, and in older buildings may disturb lead paint, asbestos-containing render or lime mortars of unknown composition.

Under the Work Health and Safety Regulation 2025 (NSW), section 291 defines high risk construction work. Tuck pointing and repointing routinely involves a risk of a person falling more than 2 metres (s291(a)), triggering the requirement under section 299 for a Safe Work Method Statement to be prepared before work commences. Controls follow the hierarchy in section 36, prioritising elimination of falls through ground-level pre-assembly or full perimeter scaffold, engineering controls for silica dust (on-tool extraction and water suppression), and PPE only as a final layer.

Hazards identified

12 hazards covered, sorted by priority.

Control measures

Hierarchy-of-controls order: elimination → substitution → isolation → engineering → administrative → PPE.

1. 1Eliminate work at height where feasible by pre-assembling test panels at ground level and by scheduling façade repointing to coincide with scaffold already erected for other trades.
2. 2Substitute dry mechanical raking with hand chisel and hawk pointing on friable heritage lime mortars, and substitute high-silica OPC mortars with lime-based mixes appropriate to the substrate (reducing both silica content and grinder use).
3. 3Erect a compliant modular scaffold with guardrails, mid-rails and toeboards to AS/NZS 1576 for any working face above 2 m; where scaffold is not practicable, use an EWP operated by a licensed high risk work operator with a travel-restraint harness anchored to a manufacturer-rated point.
4. 4Implement engineering controls for RCS: fit angle grinders and oscillating tools with on-tool shrouded extraction connected to an H-class or M-class HEPA vacuum tested to AS/NZS 60335.2.69, and/or wet-cut with a controlled water feed; isolate the work zone with barriers and signage.
5. 5Before work on any structure built prior to 2004, obtain the asbestos register (WHS Regulation 2025 s422) and a lead-paint assessment; where ACM or lead is suspected, engage a licensed asbestos removalist or use lead-safe work practices to AS 4361.2 before repointing proceeds.
6. 6Conduct a pre-start structural assessment of parapets, chimneys and lintels; brace or prop unstable sections, exclude the public with hoarding and overhead protection to AS/NZS 4576, and rake mortar in short vertical runs to preserve wall stability.
7. 7Test and tag all 240 V leads and tools quarterly to AS/NZS 3760, protect circuits with a 30 mA RCD, and observe a minimum 3 m no-go zone from live overhead conductors unless the network operator has isolated or insulated them.
8. 8Select angle grinders fitted with dead-man switches, wheel guards and Type 1 reinforced discs rated for the tool speed; conduct daily pre-start inspections and prohibit the removal of guards.
9. 9Provide and enforce PPE selected to the residual risk: P2 or P3 respirator fit-tested to AS/NZS 1715 with facial-fit records; safety glasses and face shield to AS/NZS 1337.1; anti-vibration gloves; nitrile gloves under work gloves for wet mortar; Class 5 hearing protection to AS/NZS 1270; steel-cap boots and hi-vis to AS/NZS 4602.1.
10. 10Implement administrative controls: rotate workers to limit continuous grinder use to under 2 hours per shift for HAVS management, provide silica health monitoring under WHS Regulation 2025 s368 where exposure is reasonably likely, and maintain an air-monitoring program per AS 2985.
11. 11Establish a silica dust exclusion zone with signage, decontamination area for boot and clothing cleaning (HEPA vacuum only, never compressed air), and wash facilities for cement-contaminated skin; contain and dispose of dust and slurry as controlled waste.
12. 12Verify every worker holds a current CPCCWHS1001 White Card and evidence of silica awareness training; conduct SWMS consultation and sign-on with all workers under section 47 of the WHS Act 2011 (NSW) before work starts, and review the SWMS under section 302 of the WHS Regulation 2025 whenever controls change, an incident occurs, or a HSR requests review.

Applicable Codes of Practice

High-Risk Construction Work triggered

Worked example

A three-person pointing crew is engaged to repoint the front façade and two chimneys of a Federation-era terrace in Paddington, Sydney. The building was constructed in 1908 with lime mortar; a c.1970s render patch is present near the parapet. Working height at the parapet is 7.2 m. The PCBU erects a modular scaffold to AS/NZS 1576 across the full façade with guardrails, mid-rails, toeboards and a fully planked working deck, eliminating the fall-from-height risk. Before work commences, the asbestos register is reviewed and a licensed asbestos assessor confirms the 1970s render is non-ACM; a lead swab of the painted window reveals detected lead, so pointing is sequenced to avoid disturbing painted surfaces. Mortar is raked using oscillating multi-tools fitted with on-tool HEPA extraction (H-class vacuum) and hand chisels for the fragile lime joints. All operators wear P2 half-face respirators fit-tested to AS/NZS 1715, safety glasses with side shields, Class 5 earmuffs and anti-vibration gloves. The SWMS is signed on by all three workers, each holding a current CPCCWHS1001 White Card, and reviewed on day 4 when a fourth worker joins the crew.

Related legislation

• Work Health and Safety Act 2011 (NSW)
• Work Health and Safety Regulation 2025 (NSW)
• Protection of the Environment Operations Act 1997 (NSW) — dust and waste emissions
• Heritage Act 1977 (NSW) — where works affect listed items
• Dangerous Goods (Road and Rail Transport) Act 2008 (NSW) — where lead or asbestos waste is transported
• Public Health Act 2010 (NSW) — lead notification obligations

Frequently asked questions