Safe Work Method Statement

Stone Pitching Safe Work Method Statement

Comprehensive Australian WHS Compliant SWMS

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5 sec
Creation Time
100%
Compliant
2,000+
Companies
$3.6K
Fines Avoided

Avoid WHS penalties up to $3.6M—issue compliant SWMS to every crew before work starts.

Stone pitching, also known as rock pitching or stone revetment, is a specialized civil engineering technique used to protect slopes, riverbanks, shorelines, and drainage channels from erosion caused by water flow, wave action, or surface runoff. This traditional but highly effective erosion control method involves placement of large rock or stone materials on prepared slopes in interlocking patterns that resist erosive forces while allowing water drainage and maintaining slope stability. Stone pitching operations combine heavy manual handling of rock materials, work on steep or unstable slopes, operation in or near water environments, and coordination with excavation and material placement activities, creating a complex work environment requiring comprehensive safety controls to protect workers from the numerous hazards inherent to this specialized construction activity.

Unlimited drafts • Built-in WHS compliance • Works across every Australian state

Overview

What this SWMS covers

Stone pitching, also known as rock pitching or stone revetment, is a specialized civil engineering technique used to protect slopes, riverbanks, shorelines, and drainage channels from erosion caused by water flow, wave action, or surface runoff. This traditional but highly effective erosion control method involves placement of large rock or stone materials on prepared slopes in interlocking patterns that resist erosive forces while allowing water drainage and maintaining slope stability. Stone pitching operations combine heavy manual handling of rock materials, work on steep or unstable slopes, operation in or near water environments, and coordination with excavation and material placement activities, creating a complex work environment requiring comprehensive safety controls. Stone pitching works typically involve several distinct phases including site preparation through vegetation clearing and slope excavation to design profiles, placement of filter fabric or graded filter layers preventing soil migration through stone voids, delivery and stockpiling of stone materials meeting specified size gradations (typically 150-600mm diameter for hand-placed stone pitching), manual or mechanical placement of individual stones in interlocking patterns following specified slopes and alignments, and grouting or filling voids between stones where enhanced stability is required. The scale varies from small drainage works involving a few tonnes to major riverbank protection involving thousands of tonnes of rock. The selection of stone materials considers durability, size and shape, density, and local availability. Engineering specifications define required stone size ranges and gradations ensuring appropriate mixture of large anchor stones and smaller infill materials. Quality control verifies stones meet specifications, placement patterns achieve required coverage, and final profiles match design grades protecting entire slope surfaces.

Fully editable, audit-ready, and aligned to Australian WHS standards.

Why this SWMS matters

Stone pitching operations involve multiple high-risk activities triggering mandatory SWMS requirements including manual handling of heavy materials (stones typically 20-100kg), work on slopes often exceeding 30-45 degrees creating fall risks, work near water bodies presenting drowning hazards, operation of mobile plant for material delivery and placement, and potential interaction with underground services during excavation. The combination has resulted in serious injuries including workers falling down steep slopes, crush injuries from dropped stones, drowning, and mobile plant incidents. The physical demands cause significant musculoskeletal injuries affecting workers' long-term capacity. Repetitive heavy lifting creates acute back injuries and chronic conditions. Working in bent postures on steep slopes amplifies strain. The uneven surface provides unstable footing. Many projects occur in remote locations with limited emergency access, meaning injuries may have delayed treatment. Environmental incidents can result in regulatory prosecution and project suspension. Sediment discharge violates water quality standards. Damage to protected habitats leads to enforcement action. Work outside approved timeframes results in prosecution. The technical quality affects long-term performance with poorly installed stone pitching failing during floods, requiring costly repairs and potentially allowing downstream damage.

Reinforce licensing, insurance, and regulator expectations for Stone Pitching Safe Work Method Statement crews before they mobilise.

Hazard identification

Surface the critical risks tied to this work scope and communicate them to every worker.

Risk register

Falls Down Steep Slopes During Stone Placement

high

Workers placing stone on steep slopes face significant fall risks from losing footing on loose or unstable surfaces, slipping on wet or muddy ground, overbalancing when positioning heavy stones, or when slopes fail beneath workers during construction. Stone pitching typically occurs on slopes of 30-60 degrees or steeper, approaching or exceeding the angle of repose for loose materials. The surface of partially completed stone pitching is inherently unstable with voids between stones creating trip hazards and uneven footing. Workers must lean forward and down while positioning stones, shifting their center of gravity in unstable directions. Wet conditions from rain, dew, or proximity to water bodies increase slip risks substantially. Falls down steep slopes can involve tumbling or sliding for 5-20 metres or more before stopping, with workers striking rocks and the ground surface multiple times during descent. The remote locations of many stone pitching sites delay emergency response with access to injured workers on steep slopes extremely difficult for ambulance crews. Seasonal timing of stone pitching work often coincides with wet weather periods when erosion is most active, creating worst-case conditions for slip and fall risks.

Consequence: Fatal head injuries from striking rocks during tumbling falls down slopes, serious fractures including spinal injuries, limb fractures, and pelvic fractures from impact with slope surface and rocks, traumatic brain injuries even when hard hats are worn due to multiple impacts, and compound injuries where falls culminate in workers landing in water bodies creating drowning hazards in addition to fall injuries.

Manual Handling of Heavy Stone Materials

high

Stone pitching requires workers to repeatedly lift, carry, and position stones weighing 20-100 kilograms or more throughout work shifts. Manual handling occurs in adverse conditions including steep slopes requiring workers to walk uphill and downhill while carrying stones, uneven footing on loose materials, awkward postures bending and twisting to position stones in specific orientations, and often in team lifts requiring coordination between multiple workers. The irregular shape of stones makes grasping difficult with limited handhold opportunities, while sharp edges can cause hand injuries and affect grip. Workers may attempt to move stones exceeding safe manual handling limits due to production pressure or limited mechanical handling equipment availability. Cumulative loading over days and weeks of continuous stone pitching work causes progressive fatigue and injury accumulation. The physical demands select for younger, stronger workers creating age discrimination concerns and fail to accommodate workers with pre-existing back conditions or reduced strength. Inadequate recovery time between stone pitching shifts prevents muscle recovery and increases injury susceptibility.

Consequence: Acute lower back injuries including muscle strains, ligament damage, and disc herniation from sudden heavy lifts or awkward postures, chronic degenerative spine conditions developing over years of heavy manual handling, shoulder and arm injuries from repetitive overhead positioning of stones, hand injuries including crush injuries, lacerations from sharp stone edges, and finger fractures from dropping or mishandling stones, and long-term disability requiring retraining for alternative work when musculoskeletal capacity is permanently reduced.

Drowning in Adjacent Waterways

high

Stone pitching work frequently occurs immediately adjacent to rivers, creeks, drainage channels, or coastal waters, with workers operating within 1-2 metres of water edges and sometimes standing in shallow water while placing stones. Drowning risks arise when workers fall into water from loss of footing on steep banks, when undertaking stone placement below water level, when rising water levels from rain or tidal changes inundate work areas, or when workers attempt water rescue of dropped tools or materials. Water bodies where stone pitching occurs often have strong currents, cold water temperatures, limited visibility from turbidity, and underwater obstacles including submerged logs, debris, and the stone pitching itself. Workers may not be competent swimmers or may have swimming ability compromised by wearing heavy work boots, tool belts, and clothing that becomes waterlogged. Panic responses when unexpectedly immersed can cause inhalation of water even in shallow depths. Remote locations and lack of immediate rescue equipment means drowning can occur before emergency response arrives. Seasonal timing during high-flow periods when erosion is active creates maximum water hazard conditions.

Consequence: Fatal drowning from cold water immersion, inability to swim while wearing heavy clothing and boots, impact injuries from being swept downstream over rocks or obstacles by strong currents, hypothermia from prolonged cold water immersion even when workers avoid drowning initially, and traumatic stress affecting workers who witness drowning incidents of coworkers.

Struck by Rolling or Falling Stones

high

Stones placed on steep slopes can roll or slide downslope if not properly positioned, striking workers below with substantial force. Rolling hazards occur when stones are inadequately keyed into slope surface or underlying stones, when slopes are too steep for stable stone placement without mechanical restraint, during placement of upper stones that dislodge lower stones, or when equipment operators inadvertently push stones over slope crests. Individual stones weighing 50-100 kilograms rolling down 30-60 degree slopes achieve significant velocity and kinetic energy capable of causing serious crush injuries. Multiple stones can be dislodged creating cascading failures affecting large slope sections. Workers below slope actively working on stone placement have limited ability to see upslope hazards and may not hear warnings due to noise from equipment and water. The progressive nature of stone pitching work means workers are continuously positioned below recently placed stones that may not yet be fully stable. Inadequate supervision allowing inexperienced workers to place stones without understanding stability requirements increases dislodgement risks.

Consequence: Fatal crushing injuries when large stones strike workers' heads or torsos, serious fractures and traumatic injuries from impacts with rolling stones, multiple casualties when cascading stone failures affect several workers simultaneously, and project delays while investigations are conducted and additional safety controls implemented following serious rolling stone incidents.

Mobile Plant Operations on Slope Crests

high

Excavators and other mobile plant operate on or near slope crests to deliver stone materials, position stones, and conduct final grading. Plant operations near slope crests create risks of plant tip-over into slope area if crest edges fail under equipment loading, collisions with workers on slopes who are not visible to operators, and dropped or ejected stones from excavator buckets striking workers below. The steep geometry of stone pitching slopes means excavators must reach over slope edges to place stones, extending booms and buckets significantly beyond the stable plant footprint. Ground conditions at slope crests may be undermined by construction activities or groundwater reducing bearing capacity below levels needed to support plant outrigger or track loads. Operators have very limited visibility to workers on slope faces below their operating position, with workers completely invisible in excavator blind spots. The repetitive nature of stone placement operations can reduce operator vigilance with attention focused on stone positioning rather than worker locations. Pressure to increase productivity can lead to operators working closer to slope edges than safe stability margins allow.

Consequence: Fatal crushing injuries to workers on slopes struck by excavators that tip over slope edges, serious injuries from stones dropped from excavator buckets striking workers below, excavator operator injuries or fatalities when equipment tips over slope edges and operators are ejected or crushed in operator cabs, and substantial equipment damage requiring equipment replacement and project delays.

Environmental Exposure to Weather and Wildlife

medium

Stone pitching work occurs entirely outdoors in riparian or coastal environments exposing workers to extreme weather, solar radiation, biting insects, and potentially dangerous wildlife. Summer heat combined with physically demanding manual handling creates severe heat stress risks particularly when wearing PPE that limits cooling. Solar UV exposure in open environments without shade causes sunburn and long-term skin cancer risks. Working near water bodies increases exposure to mosquitoes and other biting insects that may carry diseases. Venomous snakes including brown snakes and tiger snakes frequent waterways and may shelter under stones or in vegetation, creating bite risks when workers reach into areas without clear visibility. Spiders including redbacks may inhabit stored stone stockpiles. Crocodiles in northern Australian waterways create lethal hazards for workers operating near water. Leeches in water and wet areas attach to workers causing blood loss and potential infection. Seasonal storms including lightning can develop rapidly in afternoon periods particularly in summer, creating electrocution risks for workers on exposed slopes using metal tools.

Consequence: Heat-related illness including heat exhaustion and heat stroke requiring emergency medical treatment, skin cancer developing years after UV exposure during outdoor construction work, snake bite injuries potentially fatal without immediate antivenom treatment, insect-borne diseases including Ross River virus and dengue fever in northern locations, and lightning strike injuries or fatalities when workers fail to evacuate exposed locations before storms arrive.

Control measures

Deploy layered controls aligned to the hierarchy of hazard management.

Implementation guide

Mechanical Stone Placement Eliminating Manual Handling

Elimination

Utilizing excavators or specialized stone placement equipment to position stones eliminates manual handling of heavy materials, removing the primary musculoskeletal hazard from stone pitching operations. Mechanical placement allows precise positioning without workers needing to work on steep slopes.

Implementation

1. Specify excavators equipped with grading buckets or stone placement forks allowing controlled positioning of individual stones without manual handling. 2. Deploy excavators with extended reach capability allowing stone placement from stable positions at slope crests rather than requiring workers on slopes. 3. Position stone stockpiles within excavator reach at regular intervals along slope crest, minimizing excavator repositioning and improving placement efficiency. 4. Train excavator operators in precise stone placement techniques including stone orientation, interlocking patterns, and verification of stable positioning before releasing stones. 5. Limit manual stone handling to fine adjustment and small infill stones (maximum 25kg individual weight) that can be safely handled without mechanical assistance. 6. For projects where mechanical placement is not feasible due to access constraints or slope configurations, implement mechanical aids including stone lifting frames, pulley systems, or slide paths reducing manual handling forces required. 7. Document decisions regarding mechanical versus manual stone placement methods, with engineering justification where manual methods are selected demonstrating mechanical methods were considered and determined impractical for specific site conditions.

Fall Protection Systems and Access Control

Engineering

Installing edge protection at slope crests, deploying rope access systems for workers on steep slopes, and providing stable access platforms eliminates unprotected work on steep faces. Engineering controls provide physical fall prevention and arrest systems protecting workers throughout stone placement operations.

Implementation

1. Install temporary edge protection fencing at slope crests preventing workers and equipment from approaching slope edges within 1.5 metres, with gates allowing controlled access for stone placement under supervision. 2. Deploy horizontal lifeline systems anchored at slope crests allowing workers to attach full-body harnesses via shock-absorbing lanyards while working on slopes, providing fall arrest protection. 3. Construct temporary access stairs or ramps down slope faces using compacted fill or timber structures, providing stable footing and handrails for workers accessing lower slope sections. 4. Install platforms or benches at intervals down steep slopes creating level working areas where workers can safely position and place stones without standing on steep angled surfaces. 5. Utilize rope access techniques including abseil systems with competent rope access workers for placement on very steep slopes (>60 degrees) where other access methods are impractical, with all rope access workers holding relevant certifications. 6. Provide fall arrest training and competency assessment for all workers required to work on slopes, including harness donning, anchor point selection, and emergency response if falls occur. 7. Inspect all fall protection systems daily before work commences, verifying anchor integrity, rope and harness condition, and confirming all workers are connected before allowing slope access.

Water Safety Equipment and Exclusion Zones

Engineering

Implementing physical barriers preventing access to deep water, providing flotation devices, and establishing water rescue procedures eliminates drowning risks for workers operating near water bodies during stone pitching operations.

Implementation

1. Install temporary fencing or barriers preventing access to water deeper than knee depth (approximately 500mm), with controlled access points allowing necessary water entry under supervision. 2. Provide Type 1 personal flotation devices (PFDs) meeting AS 4758.1 for all workers required to work within 2 metres of water edges or in water, with PFDs worn for entire exposure period. 3. Deploy rescue equipment including throw bags, rescue lines, and reaching poles positioned at maximum 20-metre intervals along work areas adjacent to water, with equipment clearly marked and accessible. 4. Appoint designated water rescue personnel trained in water rescue techniques and certified in CPR and first aid, positioned to observe water hazard areas throughout work periods. 5. Implement water entry permits requiring supervisor authorization before any worker enters water, with permits documenting water depth, current velocity, temperature, planned activity duration, and designated safety watch person. 6. Monitor water levels in tidal or flow-affected waterways implementing trigger levels requiring work evacuation when rising water reaches defined heights relative to work areas. 7. Conduct water safety inductions for all workers before site access, covering PFD donning, rescue equipment location and use, and emergency procedures if workers or coworkers enter water unexpectedly.

Rolling Stone Prevention Through Placement Standards

Administrative

Establishing technical placement standards specifying how stones must be oriented, keyed into slopes, and interlocked with adjacent stones prevents dislodgement and rolling that could strike workers below. Administrative controls create clear requirements for stable stone placement.

Implementation

1. Develop detailed stone placement specifications documenting required orientation (typically with long axis parallel to slope contour), keying depth (minimum one-third of stone diameter embedded into slope surface or underlying stones), and interlocking patterns (each stone in contact with minimum 3-4 adjacent stones). 2. Require downslope-to-upslope progression of stone placement ensuring workers are always positioned above recently placed stones rather than below unstable new placement. 3. Implement exclusion zones prohibiting workers from positioning below slopes where active stone placement is occurring, with minimum vertical separation of 5 metres between placement crew and workers below. 4. Establish competent person oversight with experienced stone pitching supervisors inspecting placement progression verifying stones are adequately keyed and interlocked before additional courses are placed above. 5. Prohibit rolling or sliding stones down slopes as placement method, requiring all stones to be carried or mechanically placed in final positions preventing uncontrolled stone movements. 6. Install temporary stone retention structures including toe walls or barriers at slope base if workers must operate below active placement areas, providing protection against rolling stones. 7. Train all stone placement crews in proper keying and interlocking techniques through practical demonstration before allowing unsupervised stone placement, with ongoing monitoring and correction of inadequate placement practices.

Excavator Stability Management and Spotter Deployment

Engineering

Implementing excavator stability controls including crest setback distances, ground improvement, and spotter systems prevents excavator tip-over near slope edges and collisions with workers on slopes during mechanical stone placement operations.

Implementation

1. Establish minimum excavator setback distances from slope crests based on equipment weight and crest stability, typically minimum 3 metres for excavators under 20 tonnes with increased distances for heavier equipment or unstable ground. 2. Improve ground conditions at slope crests through placement of compacted fill, installation of timber mats distributing equipment loads, or reinforcement with geotextiles where bearing capacity is inadequate for equipment loading. 3. Deploy trained spotters with direct radio communication to excavator operators whenever workers are on slopes during excavator operations, with spotters maintaining visual contact between operators and workers preventing collisions. 4. Install barriers or exclusion zone markers on slope faces defining areas where workers must not enter during excavator operations, with workers returning to safe zones before excavator movements commence. 5. Implement slow movement protocols requiring excavators to travel and slew at reduced speeds when operating near slope edges or workers, allowing time for operators to respond if instability or worker proximity is detected. 6. Conduct daily crest stability inspections before excavator operations, checking for cracks, subsidence, or water seepage indicating ground deterioration requiring crest reinforcement or increased setback distances. 7. Prohibit excavator operation in wet weather or when ground conditions are saturated reducing bearing capacity below safe thresholds, suspending mechanical placement until ground dries and stability is restored.

Heat Stress Management and Weather Monitoring

Administrative

Implementing work-rest schedules, hydration programs, and weather monitoring prevents heat-related illness during physically demanding stone placement work in outdoor environments. Administrative controls maintain worker core temperatures within safe ranges.

Implementation

1. Monitor weather conditions including temperature and humidity calculating wet bulb globe temperature (WBGT) as heat stress indicator, implementing modified work-rest schedules when WBGT exceeds 28 degrees Celsius. 2. Implement mandatory rest breaks every hour when working in moderate heat (WBGT 28-32°C) extending to 15-minute breaks every 30 minutes during extreme heat (WBGT >32°C), with breaks taken in shaded areas away from direct sun. 3. Provide unlimited cool drinking water at work locations with minimum 1 litre per person per hour consumption target, monitoring actual water consumption to ensure adequate hydration. 4. Install shade structures or marquees at slope crest locations providing shaded rest areas and out-of-sun work zones where possible for preparation activities. 5. Schedule high-intensity manual stone placement work during cooler periods including early morning starts (6am-11am) and late afternoon work (4pm-7pm) avoiding midday heat peaks where feasible within project programs. 6. Train workers and supervisors in heat stress symptom recognition including excessive sweating, dizziness, nausea, confusion, and headaches, with clear first aid and emergency response procedures. 7. Implement buddy systems pairing workers to monitor each other for heat stress symptoms, with stop-work triggers requiring work suspension if symptoms are observed until affected workers recover.

Environmental Management and Wildlife Hazard Controls

Administrative

Developing environmental management procedures and wildlife management protocols prevents environmental incidents and protects workers from wildlife hazards during stone pitching in sensitive riparian or coastal environments.

Implementation

1. Obtain all required environmental approvals and permits before work commences including waterway work permits, vegetation clearing permits, and threatened species management authorities where applicable. 2. Implement sediment and erosion controls including silt fencing, sediment basins, and progressive stabilization preventing sediment discharge to waterways during construction, with daily inspections and maintenance. 3. Conduct pre-clearance surveys before vegetation removal or stone placement identifying protected species or habitats requiring retention or relocation, with qualified ecologists conducting surveys and supervising sensitive clearing. 4. Establish timing restrictions avoiding work during breeding or nesting seasons for protected species as specified in environmental approvals, typically restricting in-water works to specific months. 5. Implement snake awareness training for all workers educating on local venomous species, typical habitats, and first aid procedures for snake bite, with snake-proof gaiters provided for workers operating in high-risk areas. 6. Deploy wildlife monitors in high-risk locations (particularly northern crocodile habitats) maintaining watch for dangerous wildlife and alerting workers to evacuate if animals are detected approaching work areas. 7. Conduct environmental monitoring documenting compliance with permit conditions including water quality testing, vegetation retention verification, and wildlife interaction records throughout project duration.

Personal protective equipment

Steel Toe-Capped Safety Boots with Ankle Support

Requirement: Steel toe-capped boots meeting AS/NZS 2210.3 with high ankle support and aggressive tread pattern for steep slope traction

When: Mandatory for all stone pitching workers due to crush hazards from heavy stones and fall risks on steep slopes. Ankle support critical for maintaining stability when working on angled surfaces and uneven ground.

Hard Hat

Requirement: Type 1 hard hat complying with AS/NZS 1801 protecting against impact from dropped or rolling stones

When: Required for all workers on slopes or within 10 metres of active stone placement areas where overhead hazards from rolling stones exist. Chin straps recommended preventing dislodgement during falls.

Heavy-Duty Work Gloves

Requirement: Cut-resistant and puncture-resistant gloves rated to AS/NZS 2161.2 Level 5 with reinforced palms and fingers

When: Mandatory when handling stones to protect against sharp edges, rough surfaces, and crush injuries from stone placement. Replace gloves when excessive wear reduces protection effectiveness.

High-Visibility Clothing Class D

Requirement: High-visibility vest or shirt meeting AS/NZS 4602.1 Class D with fluorescent background and retroreflective strips

When: Required for all workers to ensure visibility to excavator operators and other plant operators. Critical for workers on slopes who may be positioned in operator blind spots.

Personal Flotation Device (PFD) Type 1

Requirement: Type 1 PFD meeting AS 4758.1 providing 150N buoyancy with collar supporting head above water for unconscious wearers

When: Mandatory for all workers operating within 2 metres of water bodies or working in water during stone placement. Must be worn for entire exposure period, not just kept accessible.

Safety Glasses with Side Shields

Requirement: Impact-resistant safety glasses meeting AS/NZS 1337 with side shields protecting from flying stone chips and dust

When: Required when handling stones that may chip or break during placement, and when operating in dusty conditions from material handling. Face shields required when using hammers or sledges to break or adjust stones.

Sun Protection - Hat and Sunscreen

Requirement: Broad-brimmed hat or hard hat with brim attachment plus SPF 50+ broad-spectrum sunscreen applied every 2 hours to all exposed skin

When: Required for all outdoor work preventing skin cancer from extended UV exposure typical in stone pitching operations. Long-sleeve shirts and sun-protective clothing provide additional protection.

Full-Body Harness with Shock Absorber

Requirement: Fall arrest harness meeting AS/NZS 1891.1 with dorsal and frontal attachment points plus shock-absorbing lanyard rated to arrest falls

When: Required when working on slopes steeper than 30 degrees or within 2 metres of unprotected slope edges. Must be attached to approved anchor points or horizontal lifeline systems before accessing slopes.

Inspections & checks

Before work starts

  • Inspect slope conditions including stability, existing erosion, vegetation, and ground surface identifying hazards requiring control before stone placement commences
  • Check weather forecast for rain, extreme heat, and storm warnings implementing scheduling adjustments if adverse conditions predicted during work period
  • Verify stone materials meet specification requirements for size, shape, and durability by inspecting delivered stockpiles and rejecting unsuitable materials
  • Inspect fall protection equipment including harnesses, lanyards, anchor points, and horizontal lifelines for damage or wear requiring replacement
  • Check water safety equipment including PFDs, rescue lines, throw bags, and reaching poles ensuring adequate quantity and serviceable condition
  • Verify excavator stability controls including crest setback markers, ground improvement, and spotter deployment are in place before mechanical placement begins
  • Review environmental permits and approvals confirming work is authorized and all permit conditions including timing restrictions and sediment controls are met
  • Conduct toolbox meeting with all workers reviewing placement sequence, fall protection requirements, water hazards, and emergency procedures before work commences

During work

  • Monitor stone placement quality continuously verifying stones are properly keyed, oriented, and interlocked according to specifications
  • Check slope stability throughout placement operations watching for cracks, slumping, or movement indicating slope deterioration requiring work suspension
  • Verify workers on slopes remain connected to fall protection systems with periodic visual checks confirming harness connections to anchor points
  • Monitor water levels in tidal or flow-affected locations evacuating workers if rising water reaches trigger levels approaching work areas
  • Inspect sediment controls regularly including silt fencing integrity, sediment basin capacity, and runoff water quality particularly after rain events
  • Check excavator positioning and movements ensuring crest setbacks are maintained and spotters are providing effective guidance when workers are on slopes
  • Monitor worker fatigue and heat stress symptoms particularly during afternoon periods in hot weather, enforcing mandatory rest breaks
  • Verify exclusion zones below active placement areas are maintained preventing workers from positioning beneath unstable newly placed stones

After work

  • Inspect completed stone pitching sections verifying coverage, thickness, grade conformance, and stability before acceptance and handover
  • Check that all workers have safely evacuated slopes and removed fall protection equipment, with equipment inspected before storage
  • Verify all tools, equipment, and materials are secured preventing loss into waterways or creating hazards for subsequent activities
  • Document daily production including area completed, stone quantities placed, quality test results, and any deficiencies requiring rectification
  • Review any near-miss incidents or safety concerns raised during shift, identifying corrective actions required before next work period
  • Inspect environmental controls confirming sediment fencing remains intact, no discharge to waterways occurred, and vegetation protection measures remain effective

Step-by-step work procedure

Give supervisors and crews a clear, auditable sequence for the task.

Field ready
1

Site Preparation and Slope Excavation

Clear vegetation from slope area following environmental clearing permits and retention zone requirements, with clearing supervised by ecologists where protected species habitats exist. Excavate slope to design profile using excavators or dozers, creating uniform grades typically 1V:2H to 1V:1.5H (vertical to horizontal) depending on engineering specifications and soil stability. Remove all topsoil, vegetation, and unsuitable materials down to competent foundation material capable of supporting stone pitching loads. Grade slope surface smooth eliminating significant irregularities or soft spots that could cause differential settlement. Install survey control including benchmarks and slope stakes defining top of slope, toe of slope, and intermediate grade control at maximum 10-metre spacing. Verify excavated profile matches design grades within specified tolerances (typically ±50mm from design elevation). Compact slope surface using walk-behind compactors or light rollers achieving firm surface for subsequent filter layer or direct stone placement. Install temporary erosion controls including silt fencing at slope toe and diversion drains at slope crest preventing uncontrolled runoff across exposed slopes during construction. Establish stone stockpile areas at slope crest within excavator reach, with stockpiles on stable ground minimum 3 metres from slope edges preventing overloading of crest zones.

Safety considerations

Slope excavation creates unstable ground conditions—prohibit worker access to slopes during excavation and immediately after until slope stability is verified by competent persons. Clearing activities may disturb snakes or other wildlife—conduct pre-clearance surveys and have qualified wildlife handlers available if protected species are encountered. Excavation near waterways can undermine slopes or trigger collapse—maintain conservative setbacks from water edges and monitor for signs of instability.

2

Filter Layer or Geotextile Installation

Install filter protection preventing soil migration through voids in stone pitching which would cause settlement and undermining. For projects specifying graded filter layers, place 150-300mm thickness of graded aggregate (typically 5-20mm size) over prepared slope surface, hand-raking to uniform thickness and ensuring complete coverage. For projects using geotextile filter fabric, unroll fabric down slope from crest to toe, overlapping adjacent rolls minimum 300mm, and securing fabric at crest and intermediate locations using steel pins, staples, or sandbags preventing fabric movement during stone placement. When using geotextile on steep slopes (>45 degrees), deploy workers attached to horizontal lifeline systems or utilize rope access techniques preventing falls during fabric installation. Pin or stake fabric at maximum 1-metre intervals across slope width preventing billowing or displacement when stones are placed. Ensure fabric extends beyond stone pitching footprint at all edges preventing soil exposure at transitions. For underwater installations, weight fabric with temporary stones during placement preventing flotation and displacement before permanent stone placement secures fabric. Inspect fabric for tears, punctures, or inadequate overlap requiring repair before stone placement proceeds, as damaged filter layer compromises long-term stone pitching performance.

Safety considerations

Working on fabric-covered slopes is extremely slippery particularly when wet—utilize fall protection systems and avoid working on fabric during rain or when morning dew is present. Geotextile installation on steep slopes requires rope access competency—ensure workers hold appropriate certifications and utilize approved anchor points and equipment. Wind can lift and displace fabric creating entanglement hazards—secure fabric progressively during installation and suspend installation during high winds.

3

Foundation Stone Placement

Commence stone placement at slope toe working upward ensuring stable foundation before building additional courses. Select largest stones from stockpile for foundation course (typically top 20% of size gradation), positioning stones with long axis parallel to slope contour. Excavate foundation trenches at slope toe if specified, typically 300-500mm depth allowing foundation stones to be keyed below final grade. Position foundation stones using excavator where mechanical placement is specified, or manually using teams of 2-4 workers depending on stone weights, with stones lowered into position rather than dropped to prevent damage to underlying filter layers. Orient each stone with flattest face toward slope surface maximizing contact area and stability, with irregular face exposed providing rough surface for interlocking with subsequent courses. Ensure adjacent foundation stones are tightly fitted with minimal gaps, using smaller stones as wedges filling voids between larger foundation stones. Verify foundation course is level across slope width preventing differential settlement of upper courses. Key each foundation stone minimum one-third of its thickness into slope or foundation trench, providing rotational stability resisting displacement from water forces or impact from debris. Do not proceed with additional courses until foundation course is complete along entire work section and approved by supervisors.

Safety considerations

Foundation stones are typically the heaviest stones handled—strictly enforce mechanical handling requirements or team lifting with appropriate personnel and technique. Excavated foundation trenches create fall hazards—barricade open trenches and provide safe access if workers must enter trenches for stone placement. Working at slope toe places workers below slope face—station spotters watching for rolling stones or slope instability before allowing workers into toe positions.

4

Progressive Course Placement

Build successive stone courses working upward from foundation ensuring each course is complete before commencing course above. Select stones appropriate for course being placed, typically using progressively smaller stones as courses advance up slope while maintaining minimum stone dimensions specified (commonly 300-600mm diameter). Position stones in staggered pattern similar to brick courses, avoiding continuous vertical joints that create planes of weakness. Key each stone into underlying course embedding minimum one-third of stone depth into gaps and voids between lower stones. Maintain slope batter (angle) consistent with design specifications throughout placement, using string lines or batter boards as visual guides. Pack smaller stones and stone spalls (chips) into voids between larger stones maximizing contact points and interlocking effectiveness. On very steep slopes, install temporary retention stakes or deadmen anchors preventing stone movement during construction before upper courses are in place providing downslope resistance. Work in horizontal sections maximum 5-10 metres wide advancing each section to completion before proceeding laterally, preventing long sections of incomplete courses that may be unstable. Avoid working above incomplete lower sections, maintaining downslope-to-upslope progression within each horizontal section protecting workers below from rolling stone hazards.

Safety considerations

Progressive course placement requires workers to repeatedly access slopes at increasing heights—maintain fall protection systems adjusted for current working height with anchor points repositioned as work advances. Newly placed courses may not be stable until subsequent courses provide resistance—prohibit workers from standing on or walking across freshly placed stones without verifying stability. Mechanical placement becomes more challenging as distance from crest increases—monitor excavator reach and stability carefully avoiding overextension or excessive loads on slewing mechanisms.

5

Completion, Grouting, and Quality Verification

Upon reaching design top of slope elevation, verify final course alignment, grade, and coverage meet specification requirements. Install crest protection or transition stones connecting stone pitching to surrounding ground surface preventing water undermining at upstream or sides of protected section. Fill remaining voids between stones using selected spalls and smaller stone materials, working materials into gaps using hand tamping or light mechanical vibration. For projects specifying grouted stone pitching, prepare grout mixture (typically cement-sand mortar or concrete) and carefully pour into surface voids allowing grout to flow down into deeper voids, avoiding excess grout on stone faces affecting aesthetics. Conduct quality verification inspections checking that stone sizes meet specifications (verify sample stones against gradation requirements), coverage is complete with no gaps or thin areas, stone orientation provides maximum stability with proper keying and interlocking, surface profile matches design grades within tolerance, and filter layer protection is intact without damage or displacement. Measure completed work areas documenting quantities for progress payment and final as-built records. Photograph completed sections providing visual record of installation quality. Identify and mark any deficient areas requiring rectification including inadequately keyed stones, thin coverage, or profile deviations, with rectification completed before final acceptance.

Safety considerations

Grouting operations create slip hazards from wet grout on stone surfaces—implement exclusion zones preventing access to grouted areas until grout hardens, and require workers conducting grouting to use fall protection systems. Quality inspection requires personnel to access all slope sections—utilize rope access or elevated work platforms for inspection of steep areas ensuring inspector safety. Final cleanup activities can dislodge stones or create rolling hazards—supervise cleanup work and verify slope stability before permitting access for final inspection.

Frequently asked questions

What qualifications or training are required for workers conducting stone pitching?

No specific formal qualifications exist exclusively for stone pitching work, though workers should hold general construction induction (White Card) as minimum requirement for construction site access. Workers conducting manual stone placement should receive site-specific training covering proper lifting techniques to prevent back injuries, stone orientation and keying requirements for stable placement, fall protection equipment use if working on steep slopes requiring harness systems, and recognition of unstable slope conditions requiring work stoppage. Workers operating near water must complete water safety training and be competent swimmers if PFDs alone are relied upon for drowning protection—some employers require swimming proficiency tests before permitting workers near water. Excavator operators placing stones mechanically must hold high-risk work licenses for excavator operation (class CE or equivalent) and receive training in precise stone placement techniques. Rope access workers utilized on very steep slopes must hold rope access certifications (typically IRATA Level 1 minimum) demonstrating competency in rope systems, anchor installation, and self-rescue. First aid officers with current qualifications should be present on site given remote locations typical of stone pitching projects and delayed emergency service response times. Supervisors overseeing stone pitching should have demonstrated experience with similar works, understanding technical requirements for stable stone placement, quality control procedures, and safety system implementation. Develop internal competency standards for your organization defining minimum training and experience for stone pitching roles, with assessment and verification before workers are deployed to projects. Maintain training records documenting each worker's competencies as evidence of due diligence in ensuring worker capability for tasks assigned.

How do I determine if mechanical or manual stone placement is more appropriate?

Mechanical stone placement using excavators should be the default method wherever access and project scale makes mechanical placement feasible, as this eliminates manual handling hazards that cause substantial musculoskeletal injuries. Mechanical placement is generally suitable when excavator access exists along slope crests or base allowing reach to entire slope face, stone quantities justify excavator mobilization costs (typically projects exceeding 100-200 tonnes), and slope configurations permit excavator boom reach without excessive working radius or slewing over capacity. Manual placement may be necessary when site access prevents excavator delivery (remote locations, narrow access tracks, heritage sites restricting heavy equipment), slope configurations include tight radii, complex geometries, or confined areas beyond excavator reach, existing vegetation or structures must be protected from excavator movements, or stone placement is combined with other manual works making dedicated excavator deployment inefficient. For projects requiring manual placement, implement comprehensive manual handling controls including team lifting for stones exceeding 25kg individual lift weight, mechanical aids such as stone handling frames or slide paths reducing manual forces, work rotation limiting continuous manual stone handling to maximum 2-hour periods before rest breaks or task change, and ongoing monitoring for fatigue or injury with immediate medical treatment and workload adjustment if injuries occur. Consider hybrid approaches using excavators for foundation course and larger stones with manual placement of upper courses and infill materials, optimizing productivity while minimizing manual handling exposure. Conduct pre-project planning assessing placement method options with documented justification if manual methods are selected, demonstrating elimination of manual handling was considered but determined impractical for specific project conditions. Review manual handling risk assessments and incident data regularly—if manual placement is causing recurrent injuries, revisit methodology and consider alternative approaches including mechanical placement, reduced stone sizes, or modified design specifications allowing placement methods better suited to safe work practices.

What environmental permits and approvals are typically required for stone pitching work?

Stone pitching in or near waterways typically triggers multiple approval requirements under environmental and waterway management legislation. Development consent or approval from local councils is fundamental requirement covering construction in riparian zones, with consent conditions specifying timing restrictions, sediment control requirements, and environmental monitoring obligations. Waterway work permits from state water authorities are required for any works below high water mark or within defined waterway corridors, with permits specifying seasonal restrictions avoiding fish breeding periods (typically September-March in southern Australia), installation methods to minimize disturbance, and restoration requirements. Vegetation clearing permits may be required where native vegetation must be removed, with offset requirements for cleared habitat and retention zones protecting significant trees or habitat features. Where threatened species or ecological communities are present, approvals under environmental protection legislation (EPBC Act federally, or state equivalents) may be required after ecological assessments identifying impacts and mitigation measures. Cultural heritage surveys and approvals from Traditional Owners may be required in areas of Indigenous significance before ground disturbance. For coastal works, additional approvals from coastal management authorities regulating works in coastal zones may apply. Submit approval applications well in advance of planned construction (typically 3-6 months minimum) allowing processing time and responding to requests for additional information. Engage environmental consultants experienced in waterway approvals to prepare applications, conduct required surveys, and develop environmental management plans satisfying regulatory requirements. Maintain strict compliance with all permit conditions during construction including timing restrictions, sediment control standards, and monitoring requirements—non-compliance can result in work stop orders, substantial fines, and prosecution affecting organizational reputation and future approval prospects. Brief all workers on permit conditions and environmental obligations during site inductions, establishing clear procedures for environmental incidents requiring regulatory notification. Maintain environmental compliance documentation including monitoring records, incident reports, and photographic evidence of control measure effectiveness for provision to regulators if requested during or after project completion.

How should stone pitching work be modified or suspended in response to weather conditions?

Weather conditions significantly affect both worker safety and work quality during stone pitching operations, requiring defined trigger points for work modification or suspension. Heavy rain should trigger immediate work suspension as wet slopes become extremely slippery creating severe fall risks, with work resuming only after slopes drain and surface conditions improve to point where safe footing is restored. Monitor rainfall intensity during work—light rain may be manageable with enhanced fall protection and reduced work pace, but moderate to heavy rain requires evacuation. Storm warnings including lightning should trigger immediate evacuation from exposed slope positions as workers using metal tools and equipment on elevated slopes face electrocution risks if lightning strikes occur—monitor weather forecasts and Bureau of Meteorology warnings implementing evacuation with 30 minutes safety margin before predicted storm arrival. High winds (sustained winds >40 km/h or gusts >60 km/h) create hazards for excavator stability near slope crests, increase stone dropping risks during mechanical placement, and can displace geotextile filter fabrics—suspend works during high wind periods. Extreme heat (forecast maximums >38°C or WBGT >32°C) requires modified work schedules with increased rest break frequency, earlier start times utilizing cooler morning periods, and suspension of manual placement work during peak afternoon heat. Flooding or rapidly rising water levels in adjacent waterways trigger immediate evacuation as working areas can be inundated creating drowning risks—establish trigger water levels measured at staff gauges with evacuation protocols when levels reach defined thresholds. Cold weather (<5°C) increases hypothermia risks if workers fall into cold water and reduces manual dexterity affecting stone handling—provide adequate warming facilities and cold-weather PPE if work must proceed. For projects spanning extended periods, plan weather windows identifying optimal seasons for work (typically dry periods) and building weather contingency into programs recognizing weather delays are probable for outdoor waterway works. Communicate weather shutdown decisions clearly to all workers with designated weather monitor reviewing forecasts daily and having authority to suspend works when conditions exceed safe working thresholds—never compromise worker safety pursuing productivity during adverse weather.

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Overview

Stone pitching works typically involve several distinct phases including site preparation through vegetation clearing and slope excavation to design profiles, placement of filter fabric or graded filter layers preventing soil migration through stone voids, delivery and stockpiling of stone materials meeting specified size gradations (typically 150-600mm diameter for hand-placed stone pitching), manual or mechanical placement of individual stones in interlocking patterns following specified slopes and alignments, and grouting or filling voids between stones where enhanced stability is required. The scale of stone pitching projects varies from small drainage channel protection works involving a few tonnes of stone placed by manual methods, to major riverbank or coastal protection involving thousands of tonnes of rock placed using excavators and requiring complex engineering design and environmental approvals. The selection of stone materials for pitching applications considers multiple factors including durability and hardness ensuring stones resist weathering and abrasion from water and debris, size and shape with angular stones interlocking more effectively than rounded river cobbles, density providing sufficient mass to resist displacement by water forces, and availability from local quarries affecting project economics and environmental footprint from transport. Engineering specifications typically define required stone size ranges using d50 notation (median stone diameter) and gradations ensuring appropriate mixture of large anchor stones and smaller infill materials. Quality control during placement verifies stones meet size specifications, placement patterns achieve required coverage and thickness, and final surface profiles match design grades protecting entire slope surfaces. Stone pitching work environments present unique safety challenges including steep slopes where workers must maintain footing while handling heavy materials, proximity to water bodies creating drowning risks and complicating emergency response, unstable ground conditions particularly on recently excavated slopes or areas with high groundwater, interaction with mobile plant delivering and placing stone materials, and environmental conditions including weather exposure, wildlife hazards in natural environments, and water quality concerns when working in contaminated waterways. The manual handling demands are substantial with workers repeatedly lifting, carrying, and positioning stones weighing 20-100 kilograms or more throughout work shifts. The requirement to work on steep faces, often in awkward positions, compounds manual handling strain and creates additional fall risks. Environmental considerations significantly influence stone pitching operations with works often occurring in sensitive riparian or coastal zones requiring environmental permits, timing restrictions to avoid breeding seasons for protected species, water quality monitoring preventing sediment discharge during construction, and vegetation protection measures for retained native plants. These environmental obligations add complexity to work planning and may restrict available working windows to specific seasons or weather conditions. Coordination with regulatory authorities including environmental agencies, waterway managers, and local councils is typically required before work commences, with ongoing compliance monitoring throughout project duration. Stone pitching SWMS must integrate both worker safety controls and environmental protection measures recognizing that environmental incidents can have significant consequences for project approvals and organizational reputation.

Why This SWMS Matters

Stone pitching operations involve multiple high-risk activities triggering mandatory SWMS requirements under WHS regulations including manual handling of heavy materials (stones typically 20-100kg), work on slopes often exceeding 30-45 degrees creating fall risks, work near water bodies presenting drowning hazards, operation of mobile plant for material delivery and placement, and potential interaction with underground services during site preparation excavation. The combination of these hazards in challenging work environments has resulted in serious injuries and fatalities across the construction sector including workers falling down steep slopes sustaining fractures and head injuries, crush injuries from dropped or rolling stones, drowning when workers fall into waterways, and mobile plant incidents when excavators operate on slope crests. The physical demands of stone pitching work cause significant musculoskeletal injuries affecting workers' long-term capacity and generating substantial workers' compensation costs. Repetitive heavy lifting of stones throughout shifts creates acute back injuries and chronic degenerative conditions affecting spine and joints. Working in bent or twisted postures on steep slopes while positioning stones amplifies strain on lower back and knees. The uneven, loose surface of partially completed stone pitching provides unstable footing increasing slip and fall risks. Many stone pitching projects occur in remote locations with limited access for emergency services, meaning serious injuries may have delayed treatment affecting outcomes. Comprehensive manual handling controls and emergency response planning are critical components of stone pitching SWMS. Environmental incidents during stone pitching works can result in regulatory prosecution, project suspension, and substantial remediation costs. Sediment discharge from exposed slopes during rain events violates water quality standards, triggering environmental protection orders and fines. Damage to protected vegetation or wildlife habitats leads to enforcement action and mandatory offset requirements costing many times the original project value. Work conducted outside approved timeframes during fish breeding seasons or bird nesting periods results in prosecution and reputational damage affecting future project approvals. Integrating environmental controls into stone pitching SWMS demonstrates commitment to sustainable construction practices and reduces regulatory intervention risks. The technical quality of stone pitching installation directly affects long-term performance with poorly installed stone pitching failing during flood events, requiring costly emergency repairs and potentially allowing downstream erosion damage. Stone pitching failures can undermine critical infrastructure including roads, bridges, and buildings, with liability implications for contractors whose work did not meet engineering requirements. Investment in proper installation techniques, quality control, and worker training ensures stone pitching achieves design performance over 20-50 year service lives, protecting both workers during construction and communities relying on infrastructure protected by erosion control works. SWMS establishing clear installation procedures, quality verification, and competency requirements support both safety and technical objectives.

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