Job Hazard Analysis · Masonry

Job Hazard Analysis: Tuckpointing and repointing

Removing deteriorated mortar from brick or block joints with a handheld angle grinder fitted with a dust shroud and vacuum, plus hand tools. Joints are then cleaned and refilled with fresh mortar. Work is done from ground level, ladders, or supported scaffolds on exterior walls. Hazards include crystalline silica dust, falls, noise, power tools, wet cement, and outdoor heat or cold.

Published 2026-10-23

A general example for this task. Your JHA should reflect your crew, equipment and site — review it with a competent person before work starts.

Steps, hazards and controls

Step	Hazard	Risk	Controls
1. Set up access: erect and inspect the scaffold or ladder, and barricade the work area below.	Fall from scaffold or ladder while working on the wall	High	Do the low joints from the ground when you can, so less work happens at height. Fully plank the scaffold. Install guardrails on open sides when the platform is more than 10 ft up, and set base plates and mudsills on firm ground. A competent person inspects the scaffold before each shift and after any change or storm. Extend extension ladders 3 ft above the landing, set them at a 4-to-1 angle, and tie them off. Keep 3 points of contact.
	Falling bricks, tools, or mortar hitting people below	Medium	Install toeboards or debris netting on the scaffold. Barricade and post signs under the work area. Keep the public and other trades out. Wear a hard hat on and around the scaffold.
2. Inspect the wall and set up dust controls: check for loose brick and old paint or coatings, then connect the grinder shroud to the vacuum.	Loose or unstable brick falling during work	Medium	Tap-test the wall. Mark loose sections and report them to the supervisor before grinding. Brace or remove loose units before you work below or next to them.
	Lead dust from old painted or coated brick	Medium	Test painted surfaces for lead before grinding. If lead is found, stop and get the supervisor's lead plan. Do not eat, drink, or smoke in the work area. Wash your hands and face before breaks.
	Electric shock from damaged extension cords or tools	Medium	Plug the grinder and vacuum into GFCI protection. Inspect cords and plugs before use. Tag out and remove any with cuts or missing ground pins. Route cords so they don't get pinched in scaffold frames or run through standing water.
3. Grind out the mortar joints with a 4.5-in or 5-in angle grinder fitted with a diamond tuckpointing blade, dust shroud, and HEPA vacuum.	Breathing respirable crystalline silica dust from cutting mortar and brick	High	Rake out soft mortar with hand tools where possible to cut down grinding time. Use the grinder only with its dust shroud connected to a vacuum with a cyclonic pre-separator and 99% or better filter. Keep the shroud flat against the wall. Empty the pre-separator and check vacuum suction often. Stop if you see visible dust escaping. Wear at least an APF 10 respirator for up to 4 hours of grinding per shift. Wear an APF 25 respirator, such as a loose-fitting PAPR, for more than 4 hours. Keep coworkers out of the dust zone.
	Blade kickback, binding, or broken blade causing cuts	High	Use only blades rated for the grinder's RPM. Keep the guard on, and never remove it. Hold the grinder with both hands using the side handle. Stand to the side of the blade's path. Unplug the grinder before changing blades. Let the blade stop fully before setting the grinder down.
	Loud noise from the grinder and vacuum	Medium	Rotate grinding duties among the crew to limit each person's time on the grinder. Wear foam earplugs or earmuffs during all grinding.
	Flying chips hitting the eyes or face	Medium	Keep the shroud on the wall to contain chips. Wear safety glasses plus a face shield while grinding.
4. Clean out the joints with a brush and HEPA vacuum, then lightly wet the joints before pointing.	Silica dust from cleaning joints	Medium	Vacuum the joints with a HEPA vacuum or rinse them with low-pressure water. Do not blow joints out with compressed air or dry sweep. Keep your respirator on until the dust is cleaned up.
	Slippery wet scaffold planks	Low	Use a spray bottle or garden sprayer, not a hose, to wet the joints. Keep planks clear of debris and puddles. Wear boots with slip-resistant soles.
5. Mix the mortar in a tub with a mixing paddle on a drill, or in a mortar mixer.	Cement dust and wet mortar causing skin burns and eye injury	Medium	Use pre-blended bagged mortar when possible. Open and pour bags slowly, low and close to the tub, with the wind at your back. Read the SDS for the mortar. Keep clean water and an eyewash bottle at the mixing station. Wear nitrile-coated gloves, long sleeves, and safety glasses. Wash any mortar off your skin right away.
	Back strain from lifting 60–80 lb mortar bags	Medium	Stage bags close to the mixer with a hand truck or forklift. Lift with your legs, keep the bag close to your body, and get help or use a two-person lift for heavy loads.
	Mixing paddle or mixer catching clothing or hands	Medium	Keep the mixer guard in place. Never reach into a running mixer. Use a drill with a side handle and brace it against your leg. Tie back loose clothing and do not wear jewelry.
6. Pack mortar into the joints with a tuckpointing trowel and hawk, then strike and tool the joints.	Hand, wrist, and shoulder strain from repetitive troweling overhead or at awkward heights	Low	Adjust the scaffold plank height so you work between waist and shoulder height. Take short stretch breaks and switch hands or tasks.
	Heat stress or cold stress while working outdoors on the wall	Medium	Schedule grinding for the cooler part of the day in hot weather. Give new workers time to get used to the heat. Provide cool water, shade, and rest breaks. Watch each other for dizziness, confusion, or shivering. In cold weather, wear layers and keep gloves and clothing dry.
	Lightning or high wind while on the scaffold	Medium	Get off the scaffold when you hear thunder or winds get strong. Wait 30 minutes after the last thunder before going back up.
7. Clean up: wash down the wall, HEPA-vacuum debris, clean tools, empty the vacuum, and take down access equipment.	Silica dust exposure when emptying the vacuum and changing filters	Medium	Use vacuum bags or bag-out systems. Empty the vacuum slowly into a closed bag, outdoors and downwind of the crew. Wear your respirator while emptying the vacuum or changing filters. Do not shake out filters. Do not use compressed air on clothing. HEPA-vacuum your clothes or change them before leaving.
	Falls or dropped parts while dismantling the scaffold	Medium	Dismantle from the top down under the competent person's direction, and keep the area below barricaded. Lower parts by hand line. Never throw them down.
	Tripping on debris, cords, and hoses	Low	Coil cords and hoses. Bag the debris and remove it from walkways at the end of each shift.

Required PPE

Respirator — Wear at least an APF 10 half-mask (N95 or P100) for grinding up to 4 hours per shift, and an APF 25 respirator such as a loose-fitting PAPR for more than 4 hours. Fit testing and medical clearance are required for tight-fitting respirators.
Safety glasses and face shield — Wear ANSI Z87.1 safety glasses at all times. Add a face shield over them while grinding.
Hearing protection — Wear foam earplugs or earmuffs during all grinding and when working near the grinder.
Hard hat — Wear it at all times on and around the scaffold and in the barricaded area.
Gloves — Wear nitrile-coated gloves for mortar work, and anti-vibration or work gloves for grinding.
Work boots and clothing — Wear slip-resistant safety-toe boots, long sleeves, and long pants to protect against cement burns.

Training

Silica hazard training: health risks, the dust controls on the grinder and vacuum, and the company's written exposure control plan.
Respirator training, medical evaluation, and annual fit test for tight-fitting respirators.
Scaffold user training from a qualified person. A competent person must oversee scaffold erection, inspection, and dismantling.
Ladder safety training.
Training in safe angle grinder use: blade selection, guards, and kickback.
Hazard communication training on cement and mortar SDS.

Emergency

If someone falls from the scaffold or ladder: stop all work, do not move the injured worker unless there is immediate danger, call 911, and give the exact site address. Send someone to meet the ambulance. Give first aid until help arrives. For mortar in the eyes, flush with clean water for at least 15 minutes and get medical care.

Official sources

29 CFR 1926.1153 — Respirable crystalline silica
29 CFR 1926.451 — Scaffolds — general requirements
29 CFR 1926.1053 — Ladders
29 CFR 1926.302 — Power-operated hand tools
29 CFR 1926.101 — Hearing protection
29 CFR 1926.102 — Eye and face protection
29 CFR 1910.134 — Respiratory protection program
29 CFR 1926.59 — Hazard communication

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General information, not legal advice. Templates and examples should be reviewed by a competent person before use. HardHat Binder is not affiliated with or endorsed by OSHA.