Employee Injury Risks in Brick Manufacturing (Employers’ Liability Guide)

Introduction

Brick manufacturing is a high-energy, high-heat environment with heavy materials, moving plant, dust, noise and shift work. Even well-run sites can face injuries from manual handling, machinery entanglement, slips and trips, forklift incidents, burns, respiratory exposure and long-term conditions like hearing loss.

If you employ staff in the UK, Employers’ Liability (EL) insurance is a legal requirement in most cases. But insurance is only one part of the picture. The best outcomes come from understanding where injuries happen, putting sensible controls in place, and keeping clear records so you can show what you did to protect people.

This guide breaks down the most common employee injury risks in brick manufacturing, how claims typically arise, and what practical steps can reduce both harm and insurance costs.

What Employers’ Liability insurance is (and why it matters)

Employers’ Liability insurance helps cover compensation and legal costs if an employee (or certain labour-only subcontractors) is injured or becomes ill because of their work and you are found legally liable.

In plain English: if someone says, “I was hurt at work because the business didn’t do enough to keep me safe,” EL is the policy that usually responds.

What EL typically covers

• Compensation for injury or occupational illness
• Legal defence costs and claimant legal costs (where you are liable)
• Some associated expenses (varies by insurer)

What EL doesn’t replace

EL doesn’t replace good safety management. Poor controls can still lead to:

• HSE enforcement action
• Production downtime and recruitment costs
• Higher premiums, excesses, and tougher terms at renewal
• Reputational damage with customers, auditors and regulators

The brick manufacturing process: where injuries tend to occur

While every site is different, injuries often cluster around:

• Raw material handling (clay, additives, sand)
• Crushing, screening, mixing and extrusion
• Cutting, setting and stacking (often repetitive and manual)
• Drying and kiln operations (heat, gas systems, confined areas)
• Packaging, palletising and despatch (forklifts, wrapping, loading)
• Maintenance shutdowns (isolation, work at height, contractors)

Understanding your “risk hotspots” by area and task is the fastest way to reduce incidents.

Top employee injury risks in brick manufacturing (and how to control them)

1) Manual handling injuries (back, shoulder, strain injuries)

Why it happens

Brick manufacturing involves heavy and awkward loads: moulds, pallets, packs, refractory materials, spares, and repetitive handling in packing areas. Even where automation exists, manual tasks still creep in during changeovers, rework and maintenance.

Common injuries

• Back strains and disc injuries
• Shoulder and rotator cuff injuries
• Repetitive strain injuries (RSI)
• Hernias

Practical controls

• Redesign tasks to remove lifts (conveyors, vacuum lifters, hoists)
• Set clear weight limits and team-lift rules
• Rotate tasks to reduce repetition and fatigue
• Provide handling training that matches real tasks (not generic videos)
• Maintain floors and access routes so people can move loads safely

2) Machinery entanglement and crush injuries

Why it happens

Extruders, rollers, cutters, conveyors, palletisers and wrapping machines all create nip points and trapping hazards. Injuries often happen during clearing blockages, cleaning, adjustment and fault-finding.

Common injuries

• Finger/hand crush injuries
• Amputations and severe lacerations
• Fractures and crush trauma

Practical controls

• Guarding that is fit for purpose and not easily bypassed
• Lockout/Tagout (LOTO) procedures for isolation and verification
• Interlocks and safe access systems where appropriate
• Permit-to-work for non-routine tasks
• Clear “no hands” tools for clearing jams (hooks, paddles)
• Supervisor checks and a culture that stops “just this once” shortcuts

3) Forklift and vehicle movements (struck-by incidents)

Why it happens

Brick plants often have mixed traffic: forklifts, telehandlers, HGVs, loading shovels and pedestrians. Busy despatch areas and tight yard layouts increase risk.

Common injuries

• Crush injuries and fractures
• Head injuries
• Fatalities in worst-case scenarios

Practical controls

• Physical segregation of pedestrians and vehicles (barriers, marked routes)
• One-way systems and speed limits with enforcement
• Banksmen for reversing and loading operations
• Forklift training, authorisation and refresher plans
• Yard lighting, mirrors, and clear signage
• Rules for phone use and distraction

4) Slips, trips and falls (including work at height)

Why it happens

Dust, clay residues, water, packaging waste, uneven surfaces, and temporary maintenance work can all create slip and trip hazards. Work at height may occur on silos, gantries, maintenance platforms, and during roof or ducting work.

Common injuries

• Sprains and fractures
• Knee injuries
• Head injuries

Practical controls

• Housekeeping standards with ownership by area
• Dust management and regular cleaning schedules
• Anti-slip surfaces and prompt repair of damaged flooring
• Safe access equipment (proper steps, platforms, MEWPs)
• Fall protection and rescue plans where required
• Permit-to-work for height tasks and contractor control

5) Heat, burns and thermal stress

Why it happens

Kilns, dryers, hot surfaces, steam lines, and hot product handling create burn risks. Thermal stress can also build up in hot environments, especially with PPE and long shifts.

Common injuries

• Contact burns
• Heat exhaustion and dehydration
• Eye injuries from heat and particulates

Practical controls

• Guarding/insulation of hot surfaces and clear signage
• Heat-stress risk assessments and hydration plans
• Job rotation and rest breaks in cooler areas
• Suitable PPE (heat-resistant gloves, face protection)
• Training on recognising early signs of heat stress

6) Dust exposure (silica, clay dust) and respiratory issues

Why it happens

Cutting, crushing, screening, and sweeping can generate dust. Some dusts may contain respirable crystalline silica (RCS), which is linked to serious long-term health issues.

Common illnesses

• Occupational asthma
• Chronic bronchitis
• Silicosis (where RCS exposure is not controlled)

Practical controls

• Local exhaust ventilation (LEV) where dust is generated
• Wet suppression where appropriate
• Enclosed processes and extraction on cutting points
• RPE selection, fit testing, and maintenance
• Air monitoring and health surveillance where required
• Avoid dry sweeping; use vacuum systems designed for dust

7) Noise-induced hearing loss

Why it happens

Crushers, conveyors, fans, cutting equipment and mobile plant can create sustained high noise levels. Hearing damage is often gradual, so it’s easy to miss until it becomes a claim.

Common outcomes

• Noise-induced hearing loss
• Tinnitus

Practical controls

• Noise surveys and zoning
• Engineering controls (enclosures, dampening, maintenance)
• Hearing protection with correct selection and training
• Health surveillance (audiometry) where required
• Clear signage and enforcement in high-noise areas

8) Hand-arm vibration and tool-related injuries

Why it happens

Maintenance teams may use grinders, impact tools, breakers and other vibrating equipment. Poor maintenance and long exposure can increase risk.

Common outcomes

• Hand-arm vibration syndrome (HAVS)
• Carpal tunnel symptoms

Practical controls

• Trigger-time monitoring and exposure management
• Tool maintenance and selection of low-vibration options
• Training on grip, posture and breaks
• Health surveillance where required

9) Chemical exposure (additives, fuels, cleaning agents)

Why it happens

Brick manufacturing can involve additives, oils, greases, kiln fuels, and cleaning chemicals. Risks increase when decanting, mixing, or using chemicals in poorly ventilated areas.

Common injuries/illness

• Dermatitis and skin burns
• Eye injuries
• Respiratory irritation

Practical controls

• COSHH assessments that match actual products and tasks
• Closed transfer where possible; safe decanting stations
• Eyewash stations and quick access to first aid
• Skin care programmes and suitable gloves
• Training on Safety Data Sheets (SDS) and emergency response

10) Maintenance shutdowns and non-routine work

Why it happens

Many serious incidents happen during maintenance: isolations missed, guards removed, time pressure, and multiple contractors working at once.

Common injuries

• Crush/entanglement during testing
• Falls from height
• Electric shock

Practical controls

• Robust permit-to-work system (electrical, mechanical, hot works, confined spaces)
• Isolation registers and verification steps
• Contractor vetting and supervision
• Pre-job briefs and post-job handover checks

How Employers’ Liability claims typically arise in brick manufacturing

Most EL claims come down to one (or more) of these issues:

• A risk assessment existed but wasn’t followed in practice
• Training was completed, but not refreshed or not task-specific
• Guards or interlocks were bypassed “to keep production moving”
• Maintenance was overdue or records were missing
• PPE was issued but not enforced or not suitable
• Near misses were reported but not investigated properly

From an insurance point of view, documentation matters. If you can show you identified the risk, put controls in place, trained people, and maintained equipment, you are in a much stronger position.

What good documentation looks like (without drowning in paperwork)

You don’t need perfect paperwork. You need clear, consistent evidence:

• Risk assessments and method statements (reviewed and signed)
• Training records and competency sign-offs
• Maintenance logs for plant, guards, LEV and lifting equipment
• Incident and near-miss reports with corrective actions
• PPE issue records and fit-test records for RPE
• Contractor permits and inductions

A simple rule: if it’s important enough to do, it’s important enough to record.

Insurance tips: getting your EL cover right

When arranging or renewing Employers’ Liability for a brick manufacturing site, insurers typically want to understand:

• Your activities (manufacturing only vs quarrying, haulage, installation)
• Number of employees and use of temporary labour
• Claims history and any HSE notices
• Plant and process hazards (kilns, dust control, vehicle movements)
• Your safety management approach (risk assessments, training, audits)

Common add-ons to consider

Depending on your operation, you may also need:

• Public Liability (for visitors, customers, third parties)
• Products Liability (if you supply bricks/blocks into the market)
• Contractors’ All Risks / Engineering (for plant and projects)
• Business Interruption (if a fire or breakdown stops production)

An EL policy is essential, but it’s rarely the only cover a manufacturing business needs.

Quick checklist: practical actions to reduce injuries and claims

• Separate pedestrians and vehicles in yards and despatch areas
• Review guarding and isolation procedures for jam-clearing tasks
• Improve dust control (LEV, housekeeping, RPE fit testing)
• Run noise surveys and act on results
• Tighten permit-to-work for maintenance and shutdowns
• Refresh manual handling controls and redesign repetitive tasks
• Keep training and maintenance records tidy and accessible

When to get advice

If you’ve had a near miss, a pattern of minor injuries, or you’re expanding production, it’s worth reviewing your risk controls and your insurance programme together. Small changes in layout, training and documentation can make a big difference to both safety outcomes and premiums.

Call to action

If you run a brick manufacturing business and want a quick review of your Employers’ Liability and wider commercial insurance, we can help you sense-check cover, limits and key exclusions — and talk through practical risk improvements that insurers like to see. Get in touch for a quote or a no-pressure chat.