Harris Brick Safety Systems

The Challenge

For almost 30 years, Carl Harris built his career in bricklaying, progressing from apprentice to senior site manager. In 2018, a life-changing accident altered his path. While working on site, a wall he had built according to guidelines became unstable in high winds and collapsed, crushing his left leg. The injuries were devastating and left him unable to work for two years.

Carl faced a long and difficult recovery that brought with it financial strain and mental health challenges. Determined to keep moving forward, he retrained in health and safety and achieved an SMSTS qualification. He returned to site management, but the Covid-19 pandemic created further instability and forced him to rethink his future.

The Innovation

During lockdown, Carl revisited an idea that had been at the back of his mind for years. He began sketching out designs for a new type of wall-bracing system that could prevent the kind of collapse he had suffered from. Research revealed that nothing like his concept existed on the market, and he moved quickly to patent his invention.

The result was the Brick Bud, a patented safety system designed to hold walls steady during construction. Shaped as a light and adaptable A-Frame, the device fixes securely to the ground and can support walls in winds of up to 73 miles per hour. It is quick to set up, taking only around 90 seconds to install, and is robust enough to significantly reduce accidents, near misses, and even fatalities.

Support to go to the Next Level

Carl’s journey from idea to product was supported to take his invention to the next level. With backing from Innovate UK through the Innovation Net Zero initiative, he was able to devote his time fully to developing the Brick Bud. His participation in Tees Valley Labs: The Forge, a twelve-week accelerator delivered by Alt Labs and funded by Tees Valley Combined Authority, gave him access to mentorship, business strategy advice, and legal support with patents and contracts. The programme also helped him prepare for investment, refine stock management, and build a professional website.

Partnerships with Further Education colleges allowed Carl to introduce the Brick Bud to the next generation of construction professionals. Meanwhile, connections with major housebuilders created opportunities to test the system on live projects and begin securing commercial adoption.

Impact

The Brick Bud has already started to make a tangible difference. It is now in production and being adopted both in training environments and on construction sites. Carl has been able to demonstrate its ability to improve safety, reduce financial losses from damaged walls, and provide greater assurance that work can continue even in difficult weather conditions. His invention has also attracted international interest, and discussions are underway to bring the product into overseas markets.

Recognition has followed, with awards and local attention raising the profile of Harris Brick Safety Systems and highlighting the role of innovation in improving industry standards.

Lessons Learned

Carl’s experience demonstrates the power of turning adversity into innovation. The injury that ended his bricklaying career became the catalyst for developing a solution that has the potential to save lives and reshape safety practices across the sector. His journey shows the importance of support networks, from business accelerators and innovation funds to mentors and educators, in helping entrepreneurs bring ideas to market.

Tees Valley Labs is run by Middlesbrough innovation consultancy Alt Labs on behalf of the Tees Valley Mayor and Combined Authority and funded by the UK Government through the UK Shared Prosperity Fund.

To find out more about the Tees Valley Labs programme, go to: Tees Valley Labs | Empowering the Innovators of Tomorrow