SWMS template · Excavation & Earthworks
Rock Breaking — Safe Work Method Statement
Safe Work Method Statement for breaking rock with excavator-mounted hydraulic hammers, rock saws, handheld breakers and non-explosive rock splitting, including dust, noise, vibration and flying debris controls.
Last reviewed
- Category
- Excavation & Earthworks
- HRCW
- 2 categories
- Job steps
- 7
- Hazards rated
- 13
- PPE items
- 8
Rock breaking is slow, loud and dusty, and it puts high loads through plant and the ground around it. It is High Risk Construction Work wherever powered mobile plant is moving, which covers almost every job using an excavator-mounted hammer or rock saw, and wherever the work creates or happens in a trench or shaft deeper than 1.5 metres. This SWMS does not cover blasting. Work with explosives needs a licensed shotfirer and its own SWMS and permits from your state or territory regulator.
The hazards specific to rock breaking are flying rock fragments and steel splinters from the hammer tool, respirable crystalline silica dust (sandstone and many other rocks contain high levels of quartz), noise that often exceeds 100 dB(A) at the operator's position, whole-body vibration for the excavator operator and hand-arm vibration for handheld breakers, and vibration damage to neighbouring buildings and services. Unsupported rock faces can fail along joints and bedding planes, and the operator can tip the machine working on uneven rock benches.
Silica controls are not optional. The workplace exposure standard for respirable crystalline silica is 0.05 mg/m³ (8-hour TWA). Use water suppression at the tool, an enclosed cab with filtered air, and respiratory protection for workers on the ground. Health monitoring is required for workers at significant risk of exposure. Non-explosive alternatives such as hydraulic splitters and expansive grouts reduce noise and vibration but create their own risks of rock blow-out and alkaline chemical burns.
Plant operators must be competent on the machine and attachment, and some states require a licence or certificate for certain plant. Check your state or territory regulator. Get a dilapidation survey and vibration limits for nearby structures before you start.
Customise this template with the rock type and any geotechnical report, the method (hammer, saw, splitter or grout), the excavator and attachment details, the exclusion zone distance, the dust suppression set-up, vibration limits and monitoring points, permitted work hours for noise, and the BYDA reference.
Important: This SWMS template is a starting point only. Review and customise it for your workplace and task. The PCBU remains responsible for ensuring the SWMS is suitable for the work. Not legal advice.
High Risk Construction Work Types
- Work in or near a shaft or trench deeper than 1.5 metres, or a tunnel
- Work in an area with movement of powered mobile plant
Personal Protective Equipment
- Hard hat
- Safety glasses with side shields, plus face shield for handheld breaking
- Hearing protection (Class 5 earmuffs or earplugs and earmuffs together)
- P2 respirator (fit tested) for ground workers
- Anti-vibration gloves for handheld breakers
- Steel-capped safety boots
- High-visibility clothing
- Chemical-resistant gloves and goggles for expansive grout
Risk Assessment
RatingsCatastrophicHighModerateLow
Step 1Pre-start assessment and neighbour protection
| Hazard / Risk | Initial Risk | Control Measures | Residual Risk | Responsibility |
|---|---|---|---|---|
| Vibration damage to adjacent structures or services | High | Dilapidation survey of adjacent structures before work. Agree vibration limits and install monitoring where required. Expose services in the work area by NDD. Use smaller hammers or saw cuts near sensitive structures. | Moderate | Project Manager / Supervisor |
| Rock face failure along joints or bedding planes | High | Geotechnical assessment of faces over 1.5 m. Scale loose rock from faces before workers go below. Nobody works below an unsupported face that hasn't been inspected. | Moderate | Geotechnical Engineer / Supervisor |
Step 2Attachment fitting and plant set-up
| Hazard / Risk | Initial Risk | Control Measures | Residual Risk | Responsibility |
|---|---|---|---|---|
| Crush injury during hammer change-over | High | Change hammers on firm level ground with the attachment resting on blocks. Quick hitch locking pin fitted and checked by test before work. Hydraulics depressurised before disconnecting hoses. | Low | Excavator Operator |
| Machine tips on uneven rock | High | Prepare a level working bench. Work over the front of the tracks, not the side. Do not use the hammer to lever or lift the machine. | Low | Excavator Operator |
Step 3Breaking with excavator-mounted hammer
| Hazard / Risk | Initial Risk | Control Measures | Residual Risk | Responsibility |
|---|---|---|---|---|
| Flying rock fragments strike workers | High | Exclusion zone around the hammer, set from manufacturer guidance and site conditions and marked with barriers. Ground workers enter only after the operator stops and acknowledges. Cab fitted with front guard or impact-resistant glazing. Never fire the hammer in the air. | Low | Excavator Operator / Supervisor |
| Whole-body vibration and fatigue for the operator | Moderate | Maintain seat suspension. Plan breaks and rotate operators on long breaking shifts. Use correct down-force rather than bouncing the machine. | Low | Excavator Operator / Supervisor |
Step 4Dust control
| Hazard / Risk | Initial Risk | Control Measures | Residual Risk | Responsibility |
|---|---|---|---|---|
| Exposure to respirable crystalline silica | Catastrophic | Water spray at the tool point throughout breaking. Operator in a closed cab with filtered air and door shut. Ground workers in P2 respirators that have been fit tested. Air monitoring to confirm exposures are below the workplace exposure standard. Health monitoring for workers at significant risk. No dry sweeping. | Moderate | Supervisor / All Workers |
Step 5Handheld breaking and saw cutting
| Hazard / Risk | Initial Risk | Control Measures | Residual Risk | Responsibility |
|---|---|---|---|---|
| Hand-arm vibration injury | High | Use low-vibration breakers. Limit trigger time per worker and rotate. Anti-vibration gloves. Report tingling or numbness. | Moderate | Supervisor / Operator |
| Noise-induced hearing loss | High | Hearing protection mandatory for everyone within the marked zone. Consider double protection near hammers. Audiometric testing for workers regularly required to wear hearing protection. | Low | All Workers |
Step 6Non-explosive splitting (hydraulic splitters or expansive grout)
| Hazard / Risk | Initial Risk | Control Measures | Residual Risk | Responsibility |
|---|---|---|---|---|
| Rock blow-out or grout ejecting from the hole | High | Follow the product's hole diameter and temperature limits. Never look down a charged hole. Cover charged holes and keep people out of the area until splitting is complete. | Low | Operator |
| Alkaline chemical burns from grout | Moderate | Mix per SDS wearing goggles and chemical gloves. Eye wash available on site. | Low | Operator |
Step 7Loading broken rock and clean-up
| Hazard / Risk | Initial Risk | Control Measures | Residual Risk | Responsibility |
|---|---|---|---|---|
| Struck by plant or trucks during loading | High | Separate truck and pedestrian routes. Spotter for reversing. Truck drivers stay in cab during loading. | Low | Supervisor / Operators |
| Silica dust during clean-up | Moderate | Wet down before loading. Clean with water or an H-class vacuum, not dry sweeping. | Low | Crew |
Relevant Codes of Practice
Worker Acknowledgement
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