Method Statement : Mixing Mortar in a Cement Mixer

Explanation

Mixing mortar in a cement mixer is a critical task in the construction process, particularly for brick and block laying. The objective is to achieve a consistent and homogenous mixture of cement, sand, and water, adhering to specified ratios to ensure the structural integrity and durability of the masonry work. This process involves the use of a portable cement mixer, which utilises a revolving drum to blend the components effectively. The operator must carefully measure the materials using buckets, ensuring precision in the mix proportions. The ultimate aim is to produce a mortar that meets the required specifications for strength and workability, facilitating efficient and safe application in construction projects.

Responsibilities

• Site Supervisor: Ensure all personnel are trained and competent in operating the cement mixer safely.
• Operator: Conduct pre-use checks on the cement mixer to ensure it is in good working condition.
• Operator: Wear appropriate personal protective equipment, including dust masks, gloves, and hearing protection.
• Operator: Measure and mix materials according to specified ratios using designated buckets.
• Operator: Monitor the mixing process to ensure consistency and quality of the mortar.
• Operator: Safely discharge the mixed mortar and clean the mixer after use.
• Health and Safety Officer: Conduct regular inspections to ensure compliance with health and safety regulations.

Equipment

• Cement mixer
• Buckets
• Shovel
• Trowel
• Wheelbarrow
• Water source
• Dust mask or respirator
• Safety goggles
• Hearing protection
• Gloves
• Steel-toe boots
• High-visibility clothing

Operation

• Conduct a risk assessment to identify potential hazards and implement control measures.
• Ensure all personnel involved are trained and competent in operating the cement mixer.
• Inspect the cement mixer for any signs of damage or wear, ensuring it is in good working condition.
• Verify that the work area is clear of obstructions and hazards, maintaining a tidy and organised environment.
• Confirm that appropriate personal protective equipment (PPE) is available and worn, including dust masks, gloves, safety goggles, and hearing protection.
• Check that the electrical supply and connections are safe and suitable for use, ensuring no exposed wires or faulty plugs.
• Ensure that the cement mixer is positioned on a stable, level surface to prevent tipping or movement during operation.
• Review the mortar mix specifications and ensure that the correct ratios of cement, sand, and water are prepared and measured accurately.
• Begin by adding the required amount of water into the drum as per the specified ratio.
• Gradually add sand into the drum using a bucket, ensuring not to overload the mixer.
• Add cement to the drum, again using a bucket for accurate measurement.
• Start the mixer and allow it to run until the materials are thoroughly combined, monitoring the consistency of the mortar.
• Use the handle to tilt the drum as needed to ensure even mixing, exercising caution to avoid sudden movements.
• Once the desired consistency is achieved, carefully tilt the drum using the handle to pour the mortar into a suitable container or directly onto the work area.
• After use, turn off and unplug the mixer before cleaning.
• Remove any residual mortar from the drum and surrounding areas using appropriate tools.
• Inspect the mixer for any signs of wear or damage and report any issues for maintenance.
• Ensure all equipment is returned to its designated storage area.
• Conduct a final check of the work area to ensure it is clean and free from hazards.

Risk Assessment : Mixing Mortar in a Cement Mixer

Who might be harmed: Operators of the cement mixer | Bricklayers and block layers working nearby | Labourers assisting with the mixing process

Type of harm: Asbestosis / Lung Cancer / Mesothelioma | Respiratory damage / Asthma / COPD

Initial Risk: Severe (4) x Occasional (3) = Medium (12) Controls

• Ensure workers wear appropriate respiratory protective equipment, such as dust masks or respirators, when handling cement and sand.
• Use pre-mixed mortar where possible to minimise the need for handling dry materials.
• Dampen materials slightly before adding them to the mixer to reduce airborne dust.
• Position the mixer in a well-ventilated area to allow dust to disperse quickly.
• Implement a regular cleaning schedule to remove dust build-up around the work area.

Residual Risk: Minor (1) x Improbable (1) = Low (1)

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Entanglement : Low (1)

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Who might be harmed: Operators of the cement mixer | Labourers assisting with the mixing process

Type of harm: Amputation | Crush / Entrapment | Cuts and Abrasions | Death | Multiple / Various Injury

Initial Risk: Severe (4) x Occasional (3) = Medium (12) Controls

• Ensure all personnel wear fitted clothing and secure long hair to prevent entanglement in moving parts.
• Install and maintain appropriate guards on the mixer to cover all moving parts.
• Provide training to operators on the safe use of the cement mixer, emphasising the risks of entanglement.
• Ensure the mixer is turned off and isolated from power before performing any maintenance or cleaning.
• Establish a safe working distance around the mixer to prevent accidental contact with moving parts.

Residual Risk: Minor (1) x Improbable (1) = Low (1)

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Manual Handling Injuries : Low (1)

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Who might be harmed: Construction Workers | Labourers

Type of harm: Back / Spinal Injury | Broken Bones | Muscular Injury

Initial Risk: Catastrophic (5) x Occasional (3) = Medium (15) Controls

• Use mechanical aids such as trolleys or wheelbarrows to transport heavy bags of cement and sand to the mixer.
• Ensure that all personnel are trained in proper lifting techniques, including bending the knees and keeping the load close to the body.
• Limit the weight of individual loads by using smaller bags or dividing materials into manageable portions.
• Position the cement mixer at an appropriate height to minimise the need for bending or reaching when loading materials.
• Encourage team lifting for heavier loads, ensuring that all individuals involved are coordinated and communicate effectively.

Residual Risk: Minor (1) x Improbable (1) = Low (1)

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Slips, Trips, and Falls : Low (1)

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Who might be harmed: Operators of the cement mixer | Bricklayers and block layers | Labourers assisting with the mixing process

Type of harm: Back / Spinal Injury | Broken Bones | Cuts and Abrasions | Death | Head Injury | Multiple / Various Injury

Initial Risk: Severe (4) x Probable (4) = Medium (16) Controls

• Ensure the work area around the cement mixer is kept clean and free from obstructions or spilled materials.
• Position the cement mixer on a stable, level surface to prevent tipping or movement during operation.
• Use non-slip mats or footwear to reduce the risk of slipping on wet or uneven surfaces.
• Clearly mark and illuminate the work area to enhance visibility and awareness of potential hazards.
• Regularly inspect and maintain the cement mixer and surrounding area to identify and rectify any potential trip hazards.

Residual Risk: Minor (1) x Improbable (1) = Low (1)

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Electrical Hazards : Low (1)

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Who might be harmed: Operators of the cement mixer | Nearby workers on site | Maintenance personnel

Type of harm: Burns | Death | Electrocution

Initial Risk: Major (3) x Frequent (5) = Medium (15) Controls

• Ensure the cement mixer is regularly inspected and maintained by a qualified electrician to prevent electrical faults.
• Use a Residual Current Device (RCD) to provide additional protection against electric shock.
• Position the mixer on a dry, stable surface to prevent water ingress into electrical components.
• Ensure all electrical connections and cables are in good condition and free from damage before use.
• Keep the power cable away from water, sharp edges, and moving parts of the mixer.
• Only use extension leads that are suitable for outdoor use and have appropriate IP ratings.

Residual Risk: Minor (1) x Improbable (1) = Low (1)

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Noise Exposure : Low (1)

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Who might be harmed: Operators of the cement mixer | Bricklayers and block layers working nearby | Labourers assisting with the mixing process

Type of harm: Permanent Hearing Damage

Initial Risk: Major (3) x Occasional (3) = Medium (9) Controls

• Ensure all personnel operating or working near the cement mixer wear appropriate hearing protection, such as earplugs or earmuffs.
• Position the cement mixer away from areas where workers are not involved in the mixing process to minimise noise exposure.
• Limit the time workers spend near the operating cement mixer to reduce overall noise exposure duration.
• Conduct regular maintenance on the cement mixer to ensure it operates smoothly and quietly, reducing unnecessary noise.
• Provide training for workers on the risks of noise exposure and the importance of using hearing protection.

Residual Risk: Minor (1) x Improbable (1) = Low (1)

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Burns : Low (1)

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Who might be harmed: Operators of the cement mixer | Labourers assisting with the mixing process

Type of harm: Burns | Eye Damage | Death

Initial Risk: Major (3) x Frequent (5) = Medium (15) Controls

• Wear heat-resistant gloves to protect hands from hot surfaces or freshly mixed mortar.
• Ensure the mixer is turned off and allowed to cool before performing maintenance or cleaning.
• Position the mixer on a stable, level surface to prevent accidental tipping and contact with hot materials.
• Use tools such as shovels or trowels to handle freshly mixed mortar, avoiding direct contact with skin.
• Implement a clear work area around the mixer to prevent accidental contact with hot surfaces.

Residual Risk: Minor (1) x Improbable (1) = Low (1)

COSHH Assessment : Mixing Mortar in a Cement Mixer

Cement dust

Cement dust is a byproduct of handling and mixing cement, which is used as a binding agent in the preparation of mortar for construction purposes.

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Inhalation : Low (1)

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Who might be harmed: Bricklayers and block layers | Labourers operating the cement mixer | Nearby workers on the construction site

Type of harm: Respiratory damage / Asthma / COPD

Initial Risk: Severe (4) x Occasional (3) = Medium (12) Controls

• Use appropriate respiratory protective equipment (RPE) such as a P2 or P3 mask to prevent inhalation of cement dust.
• Ensure adequate ventilation in the work area to disperse dust particles effectively.
• Utilise dust suppression methods, such as misting with water, to minimise airborne dust during mixing.
• Implement regular cleaning procedures to remove settled dust from surfaces and equipment.
• Train workers on the hazards of cement dust and the importance of using control measures.

Residual Risk: Minor (1) x Improbable (1) = Low (1)

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Eye Contact : Low (1)

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Who might be harmed: Bricklayers and block layers | Labourers assisting with mixing

Type of harm: Eye Damage

Initial Risk: Catastrophic (5) x Frequent (5) = High (25) Controls

• Wear safety goggles or face shields to prevent cement dust from entering the eyes.
• Ensure proper ventilation in the work area to reduce airborne dust levels.
• Use water suppression methods to minimise dust generation during mixing.
• Provide eye wash stations nearby for immediate rinsing in case of exposure.
• Implement regular cleaning of work areas to prevent dust accumulation.

Residual Risk: Minor (1) x Improbable (1) = Low (1)

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Skin Contact : Low (1)

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Who might be harmed: Bricklayers | Labourers | Mixer operators

Type of harm: Burns | Dermatitis

Initial Risk: Catastrophic (5) x Probable (4) = High (20) Controls

• Wear long-sleeved clothing and trousers to minimise skin exposure to cement dust.
• Use appropriate personal protective equipment, such as gloves, that are resistant to alkaline substances.
• Apply barrier creams to exposed skin areas before commencing work with cement.
• Wash hands and any exposed skin thoroughly with soap and water after handling cement.
• Provide access to washing facilities with running water and soap near the work area.

Residual Risk: Minor (1) x Improbable (1) = Low (1)

Silica dust

Silica dust is not intentionally used but is a by-product generated from the handling and mixing of sand, which contains crystalline silica, during the mortar preparation process.

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Inhalation : Low (1)

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Who might be harmed: Bricklayers and block layers | Labourers assisting with mixing | Nearby workers on site

Type of harm: Asbestosis / Lung Cancer / Mesothelioma | Respiratory damage / Asthma / COPD

Initial Risk: Major (3) x Probable (4) = Medium (12) Controls

• Use water suppression techniques to dampen dust during mixing operations.
• Ensure adequate ventilation in the work area to disperse airborne dust.
• Provide and enforce the use of appropriate respiratory protective equipment (RPE).
• Implement regular cleaning procedures to minimise dust accumulation.
• Conduct air monitoring to assess silica dust levels and effectiveness of controls.

Residual Risk: Minor (1) x Improbable (1) = Low (1)

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Eye Contact : Low (1)

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Who might be harmed: Bricklayers | Labourers | Mixer operators

Type of harm: Eye Damage

Initial Risk: Catastrophic (5) x Occasional (3) = Medium (15) Controls

• Wear safety goggles or face shields to prevent dust from entering the eyes.
• Ensure proper ventilation to reduce airborne dust concentration.
• Use water suppression methods to minimise dust generation during mixing.
• Implement regular cleaning procedures to remove settled dust from surfaces.

Residual Risk: Minor (1) x Improbable (1) = Low (1)

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Skin Contact : Low (1)

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Who might be harmed: Bricklayers | Labourers | Mixer operators

Type of harm: Dermatitis

Initial Risk: Severe (4) x Frequent (5) = High (20) Controls

• Wear long-sleeved clothing and gloves to minimise skin exposure.
• Use barrier creams to provide an additional protective layer on the skin.
• Wash hands and exposed skin thoroughly with soap and water after handling materials.
• Provide training on safe handling practises and personal protective equipment usage.

Residual Risk: Minor (1) x Improbable (1) = Low (1)

Toolbox Talk : Mixing Mortar in a Cement Mixer

Introduction

Mixing mortar in a cement mixer is a critical task in the construction process, particularly for brick and block laying. The objective is to achieve a consistent and homogenous mixture of cement, sand, and water, adhering to specified ratios to ensure the structural integrity and durability of the masonry work. This process involves the use of a portable cement mixer, which utilises a revolving drum to blend the components effectively. The operator must carefully measure the materials using buckets, ensuring precision in the mix proportions. The ultimate aim is to produce a mortar that meets the required specifications for strength and workability, facilitating efficient and safe application in construction projects.

Hazards

Mixing mortar in a cement mixer presents several hazards that must be carefully managed to ensure the safety of all personnel involved. Inhalation of dust from cement and sand can pose respiratory risks, necessitating the use of appropriate personal protective equipment such as dust masks or respirators. The moving parts of the cement mixer, including the revolving drum and mechanical components, present a risk of entanglement or entrapment, requiring vigilance and adherence to safe operating procedures. Manual handling of heavy materials, such as bags of cement and buckets of sand, can lead to musculoskeletal injuries if proper lifting techniques are not employed. The work area around the mixer may become cluttered or slippery, increasing the risk of slips, trips, and falls. If an electric-powered mixer is used, electrical hazards must be considered, including the risk of electric shock from damaged cables or improper connections. Additionally, noise generated by the mixer can contribute to hearing damage over time, necessitating the use of hearing protection. Finally, contact with hot surfaces or freshly mixed mortar can result in burns, underscoring the importance of wearing appropriate protective clothing and equipment.

Mixing Mortar in a Cement Mixer : Rules

• Do wear appropriate personal protective equipment (PPE), including safety goggles, dust masks, gloves, and steel-toed boots.
• Do ensure the cement mixer is placed on a stable, level surface to prevent tipping.
• Do inspect the cement mixer for any damage or defects before use.
• Do follow the manufacturer’s instructions for operating the cement mixer.
• Do use the correct ratios of cement, sand, and water as specified.
• Do ensure all guards and safety devices are in place and functioning properly.
• Do keep the work area clean and free from obstructions to prevent slips, trips, and falls.
• Do use proper lifting techniques when handling materials to avoid manual handling injuries.
• Do ensure that electrical connections are safe and dry if using an electric-powered mixer.
• Do maintain a safe distance from moving parts while the mixer is in operation.
• Do switch off and unplug the mixer before cleaning or performing maintenance.
• Do report any hazards or incidents to a supervisor immediately.

Mixing Mortar in a Cement Mixer : Warnings

• Do not operate the cement mixer without proper training and authorisation.
• Do not wear loose clothing or jewellery that could become entangled in the mixer.
• Do not overload the cement mixer beyond its specified capacity.
• Do not insert hands or tools into the drum while it is in operation.
• Do not leave the cement mixer unattended while it is running.
• Do not use the cement mixer in wet conditions without ensuring proper electrical safety measures.
• Do not stand directly in front of the discharge chute when emptying the mixer.
• Do not ignore any unusual noises or vibrations from the mixer; stop and inspect immediately.
• Do not use damaged or frayed electrical cables with electric-powered mixers.
• Do not mix mortar without wearing appropriate personal protective equipment (PPE), such as dust masks, gloves, and safety goggles.

Induction Record

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