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Managing the risks of plant in the workplace COP

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Tiêu đề Managing the risks of plant in the workplace COP
Trường học Safe Work Australia
Chuyên ngành Work Health and Safety
Thể loại Code of Practice
Năm xuất bản 2019
Thành phố Sydney
Định dạng
Số trang 66
Dung lượng 2,14 MB

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Cấu trúc

  • 1. Introduction (5)
    • 1.1. What is ‘plant’? (5)
    • 1.2. Who has health and safety duties for plant at the workplace? (5)
    • 1.3. What is involved in managing risks associated with plant? (8)
    • 1.4. Information, training, instruction and supervision (11)
    • 1.5. Registering plant (12)
  • 2. The risk management process (13)
    • 2.1. Identifying the hazards (13)
    • 2.2. Assessing the risks (15)
    • 2.3. Controlling the risks (16)
    • 2.4. Maintaining and reviewing control measures (19)
  • 3. Controlling risks: from purchase to disposal (20)
    • 3.1. Purchasing and hiring plant (20)
    • 3.2. Installation and commissioning of plant (23)
    • 3.3. Using plant in the workplace (25)
    • 3.4. Making changes (26)
    • 3.5. Inspecting plant (27)
    • 3.6. Maintenance, repair and cleaning of plant (28)
    • 3.7. Storing plant (29)
    • 3.8. Decommissioning, dismantling and disposing of plant (31)
  • 4. Specific control measures (32)
    • 4.1. Guarding plant (32)
    • 4.2. Operational controls (39)
    • 4.3. Emergency stops (39)
    • 4.4. Warning devices (41)
    • 4.5. Isolating energy sources (42)
  • 5. Plant registration (45)
    • 5.1. Design and altered design registration (45)
    • 5.2. Item registration (46)
  • 6. Keeping records (48)
    • 6.1. Record keeping—plant (48)

Nội dung

Code of practice – Managing the risks of plant in the workplace CODE OF PRACTICE MANAGING THE RISKS OF PLANT IN THE WORKPLACE AUGUST 2019 NSW note This code is based on a national model code of practi.

Introduction

What is ‘plant’?

Plant includes machinery, equipment, appliances, containers, implements and tools, and any components or items fitted or connected to them It covers a diverse range of items—from lifts and cranes to computers, conveyors, forklifts, vehicles and power tools, to quad bikes, mobile plant and amusement devices—essentially everything used in operations that forms part of the plant.

Under the Work Health and Safety Act, the general duty of care applies to this type of plant, ensuring safety obligations are met However, plant that relies exclusively on manual power for operation and is designed to be primarily supported by hand—such as a screwdriver—falls outside the scope of the WHS Regulation.

Plant is a major cause of work-related death and injury in Australian workplaces, with significant risks arising from its use; severe injuries can result from unsafe operation of plant, including machinery accidents, entanglement, crushing, falls from equipment, and electric shocks Effective plant safety requires proper training, safe operating procedures, regular maintenance, and strict adherence to Australian workplace safety standards.

 limbs amputated by unguarded moving parts of machines

 being crushed by mobile plant

 sustaining fractures from falls while accessing, operating or maintaining plant

 being crushed by a quad bike rollover

 electric shock from plant that is not adequately protected or isolated, and

 burns or scalds due to contact with hot surfaces, or exposure to flames or hot fluids

Other risks include hearing loss due to noisy plant and musculoskeletal disorders caused by manually handling or operating poorly designed plant.

Who has health and safety duties for plant at the workplace?

There are a number of duty holders who have a role in managing the risks of plant in the workplace These include:

 persons conducting a business or undertaking (PCBUs)

 PCBU involving the management or control of fixtures, fittings or plant

 designers, manufacturers, importers and suppliers of plant, substances or structures

Under the Work Health and Safety (WHS) Act, workers and other persons at the workplace must take reasonable care to protect their own health and safety while on the job.

A person can have more than one duty and more than one person can have the same duty at the same time

Early consultation and identification of risks can allow for more options to eliminate or minimise risks and reduce the associated costs

Person conducting a business or undertaking

A PCBU must eliminate risks arising from plant in the workplace, or if that is not reasonably practicable, minimise the risks so far as is reasonably practicable

The WHS Regulation includes more specific requirements for PCBUs to manage the risks of hazardous chemicals, airborne contaminants and plant, as well as other hazards associated with the workplace

This duty includes ensuring, so far as is reasonably practicable:

 the provision and maintenance of safe plant, and

 the safe use, handling, storage and transport of plant

PCBUs have a duty to consult workers about work health and safety and may also have duties to consult, cooperate and coordinate with other duty holders

Persons who conduct a business or undertaking involving the management or control of fixtures, fittings or plant

Management of risks to health and safety

Control of risks arising from installation or commissioning

Preventing unauthorised alterations to or interference with plant

Proper use of plant and controls

Guarding and insulation from heat and cold

Maintenance and inspection of plant

The WHS Regulation includes specific duties for PCBUs involving the management or control of plant including requirements to:

 manage the health and safety risks associated with plant

 prevent unauthorised alterations to or interference with plant, and

 use plant only for the purpose for which it was designed unless the proposed use does not increase the risk to health or safety

A plant's lifecycle typically involves multiple people across all stages—from design and development to operation and eventual disposal Throughout this process, individuals may hold multiple roles, and the same duty can be shared by several people at the same time.

If you own and operate plant at your workplace and you decide to modify it yourself, you assume the roles of designer and manufacturer, as well as the person with management or on-site control of the plant This means you are responsible for the design integrity, safe fabrication, and ongoing operation and compliance of the modified plant.

Further information is available in SWA’s Guidance material for the safe design, manufacture, import and supply of plant

Designers, manufacturers, importers and suppliers of plant, substances or structures

Duties of persons conducting businesses or undertakings that design plant, substances or structures

Duties of persons conducting business or undertakings that manufacture plant, substances or structures

Duties of persons conducting businesses or undertakings that import plant, substances or structures

Duties of persons conducting businesses or undertakings that supply plant, substances or structures

Duties of persons conducting businesses or undertakings that install, construct or commission plant or structures

Designers, manufacturers, importers and suppliers of plants, substances or structures must ensure, as far as is reasonably practicable, that what they design, manufacture, import or supply is free from health and safety risks This obligation includes carrying out testing and analysis and providing clear, specific information about the plant or substance to enable safe handling, storage and use, thereby supporting overall health and safety compliance.

To assist in meeting these duties, the WHS Regulation requires:

 manufacturers to consult with designers of the plant

 importers to consult with designers and manufacturers of plant, and

 the person who commissions construction work to consult with the designer of

Officers, including company directors, must exercise due diligence to ensure the PCBU complies with the WHS Act and WHS Regulation This obligation includes taking reasonable steps to ensure the business or undertaking has and uses appropriate resources and processes to eliminate or minimise health and safety risks For more detail on who is considered an officer and what their duties entail, see the Interpretive Guideline: The health and safety duty of an officer under section 27.

Workers have a duty to take reasonable care of their own health and safety and not to adversely affect the health and safety of others They must comply with reasonable instructions and, as far as they are reasonably able, cooperate with health and safety policies or procedures that have been notified to them If personal protective equipment (PPE) is provided by the business, the worker should, as far as they are reasonably able, use or wear it in accordance with the information, instruction, and training provided.

Other persons at the workplace

Duties of other persons at the workplace

Visitors and other people at the workplace have a duty to take reasonable care of their own health and safety and to avoid actions that could harm the health and safety of others They must, to the extent reasonably possible, follow the reasonable instructions given by the PCBU to help them meet their obligations under the WHS Act.

What is involved in managing risks associated with plant?

Managing risks to health and safety

Management of risks to health and safety

This Code provides guidance on how to manage the risks associated with plant in the workplace using the following systematic process:

 Identify hazards—find out what could cause harm

Assess risks as needed by understanding the nature of the harm that a hazard could cause, how serious that harm could be, and the likelihood of its occurrence, so you can prioritize safeguards and controls This step helps determine the appropriate risk controls, though it may not be necessary when you are dealing with a known risk that already has established controls.

 Eliminate risks so far as is reasonably practicable

To control risks effectively, prioritize the elimination of hazards whenever reasonably practicable; if eliminating the risk isn’t feasible, implement the most effective control measures that are reasonably practicable in the circumstances, following the hierarchy of control measures Regular monitoring and review ensure these controls remain effective over time.

 Review control measures to ensure they are working as planned

Chapter 2 of this Code provides guidance on how to manage the risks associated with managing plant in the workplace by following the hierarchy of control

Further guidance on the risk management process is in the Code of Practice: How to manage work health and safety risks

Designers, manufacturers, importers and suppliers have duties to provide information about the plant to enable other duty holders to fulfil the responsibilities they have in managing the risks associated with it This information must be given to each person to whom the plant or its design is provided and must be passed on from the designer through to the manufacturer and supplier to the end user This information includes hazard information, installation and commissioning requirements, operating and maintenance instructions, safety controls, and any other risk management information necessary to ensure safe use of the plant.

 the purpose for which plant was designed or manufactured

 the results of calculations, analysis, testing or examination, and

 conditions necessary for the safe use of the plant

A PCBU must consult, so far as is reasonably practicable, with workers who carry out work for the business or undertaking and who are (or are likely to be) directly affected by a health and safety matter

This duty to consult is based on the recognition that worker input and participation improves decision-making about health and safety matters and assists in reducing work-related injuries and disease

Under the WHS Act, the definition of 'worker' is broad, so a PCBU must consult, so far as reasonably practicable, with a wide range of people who work for the PCBU and who are, or are likely to be, directly affected by health and safety matters This includes contractors and subcontractors and their employees, on-hire workers, outworkers, apprentices, trainees, work experience students, volunteers, and other people engaged by the PCBU.

Workers are entitled to take part in consultations and to be represented in consultations by a health and safety representative who has been elected to represent their work group

Workers are usually aware of the hazards and risks associated with the plant they operate, and drawing on the experience, knowledge, and input of workers makes it more likely that hazards will be identified, enabling the implementation of effective control measures.

Workers should be encouraged to report hazards and health and safety problems immediately so the risks can be managed before an incident occurs

It is important to consult workers as early as possible when planning to introduce new plant or change the way plant is used

 relevant work health and safety information is shared with workers

 workers are given a reasonable opportunity to express their views and to raise health or safety issues

 workers are given a reasonable opportunity to contribute to the decision-making process relating to the health and safety matter

 the views of workers are taken into account

 workers are advised of the outcome of any consultation in a timely manner and

 if the workers are represented by a health and safety representative, consultation must include that representative

Management commitment and open communication between managers and workers are foundational for effective consultation When leadership actively seeks workers’ knowledge and ideas and takes health and safety concerns seriously, workers are more likely to engage in the consultation process This approach builds trust, improves safety outcomes, and fosters a culture where health and safety are integrated into daily practice.

Consultation does not mean telling workers about a health and safety decision or action after it has been taken Workers should be encouraged to:

 ask questions about health and safety

 raise concerns and report problems

 be part of the problem-solving process

While consultation may not always result in agreement, agreement should be the objective as it will make it more likely the decisions are effective and actively supported

Consulting, cooperating and coordinating activities with other duty holders

Duty to consult with other duty holders

Under the WHS Act, a person conducting a business or undertaking (PCBU) must consult, cooperate with, and coordinate activities with all other persons who hold a work health or safety duty in relation to the same matter, to the extent that is reasonably practicable.

Many workplaces involve more than one business or undertaking in the management of plant-related risks, with each party potentially responsible for the same health and safety matters This shared accountability often arises because the organizations carry out similar activities or operate within the same premises, making coordination essential to ensure effective plant safety.

In such scenarios, each duty holder should exchange information to determine who is responsible for which tasks and then collaborate in a cooperative, coordinated effort to eliminate or minimize risks to the extent reasonably practicable.

Examples of where a PCBU will have a health and safety duty include where:

 the PCBU engages workers to carry out work

 the PCBU directs or influences workers in carrying out work

 other persons may be put at risk from work carried out in their business or undertaking

 the PCBU manages or controls a workplace or the fixtures, fittings or plant at a workplace

 the PBCU’s business or undertaking involves designing, manufacturing, importing or supplying plant, substances or structures for use at a workplace

 the PBCU’s business or undertaking involves installing, constructing or commissioning plant or structures at a workplace

For example, when an on-hire business assigns workers to perform tasks at another workplace, the owner or manager should exchange information with the host business to determine roles, safety responsibilities, hazard controls, required training, and communication protocols before work commences.

 if workers could be exposed to hazardous plant, and

 what each party will do to control associated risks

At a shared workplace where plant equipment such as a crane is used by several businesses, the plant owner or manager should inform the other tenants about the risks the equipment poses and work together in a cooperative, coordinated way to manage them They should identify, assess, and control these risks through joint safety measures, clear communication, and defined responsibilities for maintenance, inspections, access, and incident reporting Ongoing dialogue and aligned risk-management arrangements help prevent accidents, ensure compliant operation, and protect workers across all businesses on site.

Further guidance on consultation requirements is available in the Code of Practice: Work health and safety consultation, cooperation and coordination.

Information, training, instruction and supervision

Provision of information, training and instruction

Under the WHS Act, a person conducting a business or undertaking (PCBU) must, so far as reasonably practicable, ensure the provision of information, training, instruction, and supervision necessary to protect all persons from health and safety risks arising from work carried out as part of the business or undertaking This duty requires accessible safety information, appropriate training and clear instruction, and competent supervision to prevent incidents and injuries and to promote safe work practices across all tasks By meeting these obligations, PCBUs establish a safer workplace, empower workers with the knowledge to manage hazards, apply controls, and comply with health and safety requirements in every activity.

The PCBU must ensure that information, training or instruction provided to a worker are suitable and adequate having regard to:

 the nature of the work carried out by the worker

 the nature of the risks associated with the work at the time of the information, training and instruction, and

PCBU should, so far as reasonably practicable, deliver information, training and instruction in clear, readily understandable language to the person receiving them, ensuring their comprehension and alignment with workplace safety requirements.

Workers must be trained and have the appropriate skills to carry out a particular task safely Training should be provided to workers by a competent person

Before anyone, including workers and other persons, operates plant in the workplace, the PCBU must, as far as reasonably practicable, provide information, training, and instruction, and arrange ongoing supervision as necessary to protect them from risks arising from plant use This duty underpins workplace safety by ensuring operators have the knowledge, guidance, and ongoing oversight needed to operate plant safely and reduce potential hazards.

As a PCBU, you must provide comprehensive safety information to anyone involved in installing, commissioning, testing, maintaining, or repairing plant, as well as to those engaged in decommissioning, dismantling, or disposing of plant This information should clearly outline the types of hazards and risks the plant may pose during these activities, enabling workers to anticipate potential dangers and take appropriate precautions.

This information may be supported with safe work procedures including instructions on:

 the correct use of guarding and other control measures

 how to safely access and operate the plant

 who may use an item of plant For example, only authorised or licensed operators

 how to carry out inspections, shut-down, cleaning, repair and maintenance

 traffic rules, rights of way, clearances and no-go areas for mobile plant

 the proper use, wearing, storage and maintenance of personal protective equipment (PPE)

Emergency instructions relating to an item of plant should be clearly displayed on or near it

Training programs should be practical and hands-on, tailored to the specific needs of workers They should account for literacy levels, prior work experience, and the particular skills needed for the safe use of the plant, ensuring that training equips staff to operate equipment safely and effectively.

Supervisors should take action to correct unsafe work practices associated with plant as soon as possible Otherwise workers may think unsafe work practices are acceptable.

Registering plant

Certain items of plant and certain types of plant designs must be registered, with Appendix B listing the registrable plant designs and registrable items of plant Registrable plant designs must be design registered prior to being supplied.

Registrable items of plant must be item registered prior to being commissioned for use by a PCBU

Design registration protects a completed design that can be applied to an unlimited number of individual items It involves registering the design so its visual appearance is legally recognized across all products derived from that design The application may be submitted by the original designer or by someone who has management or control of the item or the manufacturing facility where it is produced.

Plant item registration applies to each specific item of plant, and every item must be registered The purpose of registration is to ensure the item will be inspected by a competent person and is safe to operate If you have management or control of plant, obtain a copy of the design registration from the supplier to verify that all registrable plant items are registered.

Further information on registering plant is provided in Chapter 5 of this Code.

The risk management process

Identifying the hazards

Identifying all hazards associated with plant in the workplace is the first step in risk management, involving locating items and situations that could potentially harm people Hazards generally arise from the interaction of four key aspects of work—people, tasks and procedures, equipment and plant, and the work environment—so an effective assessment considers how these elements combine to create risk and identifies where controls are needed.

 equipment, materials and substances used

 work tasks and how they are performed, and

Hazard identification begins with inspecting the workplace and observing how tasks are carried out, and it is enhanced by consulting workers, manufacturers, suppliers, and health and safety specialists Reviewing relevant information, records, and incident reports also helps reveal potential risks By combining on-site observations, stakeholder input, and documentation analysis, organizations can identify hazards early, support effective risk assessment, and strengthen workplace safety.

Typical hazards found in managing risks of plant in the workplace can include:

At an industrial plant, crane safety hazards related to bridge and gantry cranes include worn or damaged mechanical components that can compromise performance Additional risks arise from background noise that interferes with clear communication, inadequate lighting that reduces visibility, and the challenges of coordinating multiple cranes operating on the same runway.

Traffic movements in the workplace pose serious hazards Vehicles, including powered mobile plant moving around the site and reversing during loading and unloading, are frequently linked to fatalities and serious injuries to workers and members of the public To reduce these risks, implement robust traffic management with clear routes, effective signage, trained operators, and safe loading and unloading procedures.

The operating environment for crane equipment, especially tower cranes, directly affects safety by shaping potential hazards In tower crane operations, hazards may arise from structural failure, collapse, or contact or collision with other plant and structures, depending on site conditions Factors such as limited space, proximity to power lines, weather, ground stability, and the presence of nearby machinery influence the risk of accidents and damage A proactive risk assessment of the work environment helps identify these interactions, enabling appropriate controls and planning to protect workers and surrounding assets.

Further information on identifying these types of hazards is in SWA’s Workplace traffic management guidance material

When equipment is used to lift or suspend persons or loads, the person in control of that equipment at the workplace must ensure, to the extent reasonably practicable, that the lifting gear is specifically designed to lift or suspend the load This ensures the equipment’s suitability and helps manage risk by aligning the device design with the load requirements.

If it is not reasonably practicable to use plant that is specifically designed to lift or suspend the load, the person must ensure that:

 the plant does not cause a greater risk to health and safety than if specifically designed plant were used, and

 if the plant is lifting or suspending persons, the use of the plant complies with WHS Regulation clause 220: Exception—Plant not specifically designed to lift or suspend a person

The person must ensure that the lifting and suspending is carried out:

 with lifting attachments that are suitable for the load being lifted or suspended, and

 within the safe working limits of the plant

The person must ensure, so far as reasonably practicable, that:

 no loads are suspended or travel over a person unless the plant is specifically designed for that purpose

 loads are lifted or suspended in a way that ensures that the load remains under control during the activity, and

No load shall be lifted simultaneously by more than one item of plant, except when the lifting method ensures that the load on every piece of plant remains within its design capacity The lifting arrangement must be planned so that no individual unit is overloaded and all equipment operates within its rated limits.

A person with management or control of plant at the workplace should review safety information, inspect each item of plant, and observe how it is used, and they should talk with workers and their health and safety representatives to learn about their experiences with the plant they operate, inspect, or maintain, while also reviewing the manufacturer’s and supplier’s instructions for the safe setup and use of the plant.

If you hire or lease plant, consult the plant owner about potential hazards Both parties have a shared responsibility, so far as is reasonably practicable, to ensure that the equipment is safe and does not pose risks to health and safety.

Identify hazards by considering every phase of the plant's life cycle at your workplace—installation, commissioning, operation, inspection, maintenance, repair, transport, storage, and dismantling For each activity, assess whether the plant could pose risks and determine the necessary controls to prevent harm.

 cause injury due to entanglement, falling, crushing, trapping, cutting, puncturing, shearing, abrasion or tearing

Hazardous conditions in the workplace can arise from a range of factors, including harmful emissions, fluids or gases under pressure, electricity, noise, radiation, friction and vibration, fire and explosion risks, moisture, dust, and ice They can also originate from hot or cold parts, cleaning processes, and the presence of undisclosed asbestos-containing materials.

Injury can occur when operators respond to common failure modes, such as machine jams, which often stem from poor ergonomic design or controls that are difficult to reach or require high operating forces; addressing these factors with improved ergonomics, accessible control layouts, and lower force requirements can reduce injury risk and enhance overall machine safety.

Other factors to consider include:

 the condition of the plant, for example its age, maintenance history and how frequently the plant is used

 the suitability of the plant, for example is it actually being used for its intended purpose? Has it been modified from its intended use?

Plant location directly shapes the design and layout of the workplace, influencing material flow, space utilization, and the placement of equipment and workstations for efficiency When evaluating siting, it’s essential to assess how the plant’s position affects accessibility and whether workers can reach it without risking slips, trips, or falls A well-located plant supports safe, clear pathways, proper lighting, non-slip flooring, and effective housekeeping, reducing hazard exposure and improving productivity Conversely, poor placement can create congestion, awkward routes, and increased risk, underscoring the need for thoughtful integration with loading docks, pedestrian routes, emergency exits, and control areas to ensure safe, reliable access for all staff.

 abnormal situations, for example what abnormal situations, misuse or fluctuation in operating conditions can you foresee?

A checklist to assist in identifying hazards associated with plant is at Appendix C

Information about hazards, risks and control measures relating to plant in your workplace can be obtained from:

 manufacturers, importers or suppliers of the plant

 maintenance technicians or specialists, for example engineers

 regulators, unions and other organisations

 businesses or undertakings similar to your own, and

 Australian, International or other technical standards

Review incident records and data

Review records of workplace injuries and illnesses, serious incidents, plant inspection reports, maintenance logs, workers' compensation claims, and investigation results to gather information about plant hazards This evidence-based review helps identify recurring risk areas, prioritize corrective actions, and support ongoing safety management and regulatory compliance.

Assessing the risks

A risk assessment involves considering what could happen if someone is exposed to a hazard and the likelihood of it happening A risk assessment can help you determine:

 whether existing control measures are effective

 what action you should take to control the risk, and

 how urgently the action needs to be taken

Hazards have the potential to cause different types and severities of harm, ranging from minor discomfort to a serious injury or death

Many hazards and their risks are well known and already have established, accepted control measures In these cases, there is no need to perform the second step of a formal risk assessment If, after identifying a hazard, you already know the risk and how to control it effectively, you may implement the controls directly.

In some circumstances, a risk assessment will assist to:

 identify which workers are at risk of exposure

 determine what sources and processes are causing the risk

 identify if and what kind of control measures should be implemented, and

 check the effectiveness of existing control measures

The nature and severity of risks will depend on various factors

To assess the risk associated with plant hazards you have identified, you should consider the following

What is the potential impact of the hazard?

 How severe could an injury or illness be? For example, lacerations, amputation, serious or fatal crush injury, burns or loss of hearing

 What is the worst possible harm the plant hazard could cause? For example, a crane could overturn or collapse causing harm to the operator, workers and others below

How likely is the hazard to cause harm?

 How frequently are workers exposed to the hazard?

 What condition is the plant used in? For example, in a confined space, muddy or dusty environment

 What is the condition of the plant? For example, is it old and missing safety features found on new plant? Is it reliable or often needing emergency maintenance?

 If there are other people or items of plant in the vicinity, what effect do they have on the likelihood or consequence?

 Where and when is access required during the installation, operation or maintenance of plant and in an emergency?

 What work practices and procedures exist for plant safety? For example, is isolation required to carry out maintenance?

 What kinds of information, training, instruction and supervision are provided to workers and other persons who may be exposed to plant?

 Does the plant’s safety depend on the competency of its operators?

 How is work organised? For example, consider:

 the speed of the process line

 pedestrian and vehicular traffic around the plant

 time spent on repetitive tasks

 production incentives that may affect health and safety.

Controlling the risks

The WHS Regulation requires duty holders to work through a hierarchy of control measures when managing risks to health and safety associated with plant

Specific controls are required under the WHS Regulation for certain types of plant, including:

 plant that lifts or suspends loads

 plant used in connection with tree lopping

 plant with presence-sensing safeguarding systems

Under the WHS Regulation, duty holders must work through the hierarchy of control measures when managing risks, though the approach can be applied to any risk The hierarchy ranks control measures from the highest level of protection and reliability to the lowest, guiding decisions about how best to control hazards For detailed guidance on the risk management process and the hierarchy of control measures, refer to the Code of Practice: How to Manage Work Health and Safety Risks.

Always prioritize risk elimination in product design by choosing dimensions, shapes, and weights that permit safe delivery, handling, and on-site assembly at the point of use without requiring cranes or other heavy lifting equipment.

If eliminating the hazards and associated risks is not reasonably practicable, you must minimise the risk by one or more of the following:

Substitution reduces risk by replacing a hazard or hazardous work practice with a safer alternative For example, installing a conveyor system to replace forklifts can eliminate the risks associated with moving plant but may introduce new conveyor-related risks; the goal is that the overall risk of transporting material is decreased.

Isolation minimizes risk by separating the hazard or hazardous work practice from anyone exposed to it Implement physical barriers to enforce this separation, such as concrete barriers that keep mobile plant away from workers and reduce the chance of exposure Maintaining clear separation between equipment and personnel creates a safer work environment by preventing proximity to the hazard.

 Engineering controls—engineering controls are physical control measures to minimise risk For example:

 emergency brakes in a lift that are applied automatically when the lift exceeds its maximum speed

 an automatically applied control system that prevents tower cranes from colliding while sharing the same air space

Where residual risk remains, it should be minimized through administrative controls to the extent reasonably practicable For example, implementing a lockout/tagout system can ensure the plant is isolated from its energy source and cannot be operated during maintenance or cleaning work.

Any remaining risk must be minimised with suitable personal protective equipment (PPE) For example, providing workers with breathing protection, hard hats, gloves, aprons and protective eyewear

Administrative controls and PPE do not eliminate the hazard at its source They rely on human behavior and supervision, and when used in isolation they tend to be the least effective means of minimizing risk.

Applying control measures can change how work is performed In these situations, consult your workers, develop safe work procedures, and provide training, instruction, information, and supervision on the changes to ensure everyone understands and can carry out the work safely.

Typically, a combination of control measures provides the most effective way to reduce risk to the lowest level reasonably practicable For example, protecting workers from flying debris when using a concrete cutting saw can involve guarding the blade, isolating the work area, and using personal protective equipment such as a face shield.

Always check whether the control measures you choose could create new hazards For example, hiring a forklift to manage hazardous manual tasks can introduce risks from moving plant that also need to be controlled An integrated hazard assessment should consider both the original hazards and any new ones introduced by the controls, covering factors such as traffic management, operator training, visibility, and equipment stability Regular monitoring and periodic reviews help ensure the controls remain effective and do not shift risk elsewhere in the workflow.

Working near overhead and underground electric lines

Overhead and underground electric lines

As a PCBU at a workplace, you must ensure, to the extent reasonably practicable, that no person, plant or thing at the site comes within an unsafe distance of an overhead or underground electric line.

If it is not reasonably practicable to maintain the safe distance, you must conduct a risk assessment for the proposed work and implement control measures that are consistent with the risk assessment and with the requirements of the electricity supply authority responsible for the electric line.

Electric power lines pose severe safety risks, including electrocution, arcing, explosions, and fires that can cause burns, along with unpredictable cable whip that can energize nearby objects such as signs, poles, trees, or branches Overhead and underground lines carry voltages from 230 V to 400,000 V, and contact with any of these lines can be fatal You don’t have to touch a live line to be electrocuted—a flashover or arc can injure or kill a person even when they are close to a line conductor To reduce risk, stay well clear of power lines and report damaged or unsafe lines to the utility or authorities.

The following should be considered:

 Are workers or plant likely to go near electric lines? If so, how high are the electric lines and the plant?

 Are overhead electric lines hard to see in the sky or are they hidden by trees?

 Have underground electric lines been accurately located?

 Is a safety observer in place to watch plant when it is operating close to electric lines?

Has the relevant state or territory electricity supply authority been contacted to obtain information about the specific requirements for working near electric lines, including the qualifications required for workers in proximity to live conductors? Accessing this guidance helps ensure compliance with safety regulations, clarifies training and certification needs, and identifies licensing, competencies, and the personal protective equipment (PPE) required for personnel working near electric lines.

 Have emergency rescue procedures been established, including calling the electricity supply authority to isolate the electricity supply before trying to rescue a person receiving an electric shock?

Most risks around electric lines can be managed by maintaining safe working distances for people and plant, with the required distance depending on the work type and the line voltage Contact the relevant electricity supply authority to determine unsafe distances and the appropriate control measures, which may include isolating the line.

Further information about electrical safety can be obtained from your Electricity Regulator.

Maintaining and reviewing control measures

Control measures must be maintained so they remain fit for purpose, suitable for the nature and duration of work and are installed, set up and used correctly

Health and safety control measures must be regularly reviewed to confirm their effectiveness If a control measure is not effectively controlling the risk, it should be revised promptly to restore strong risk control.

Organizations must regularly review and, where necessary, revise control measures to maintain a work environment that is, so far as reasonably practicable, free from health and safety risks This ongoing process includes hazard identification, risk assessment, and the deployment of proportionate safety controls; it also requires monitoring the effectiveness of these controls and updating procedures as work processes, equipment, or regulatory requirements change to ensure continuous protection for workers.

 when the control measure does not control the risk so far as is reasonably practicable

 before a change at the workplace that is likely to give rise to a new or different health and safety risk that the measure may not effectively control

 a new or relevant hazard or risk is identified

 the results of consultation indicate that a review is necessary, or

 a health and safety representative requests a review if that person reasonably believes that:

 a circumstance in any of the above points affects or may affect the health and safety of a member of the work group represented by the health and safety representative

 the control measure has not been adequately reviewed in response to the circumstance

Common review methods include workplace inspection, consultation, testing and analysing records and data

You can use the same methods as in the initial hazard identification step to check control measures You must also consult your workers and their health and safety representatives

If problems are found, go back through the risk management steps, review your information and make further decisions about control measures.

Controlling risks: from purchase to disposal

Purchasing and hiring plant

Many injuries and illnesses related to plant equipment arise when the wrong gear is chosen for the job Before purchasing plant machinery, verify it is suitable for the intended use, the environment it will operate in, and the workers who will operate it Discuss your needs with the plant supplier, who should provide information about the equipment’s compatibility with the task, the conditions of use, operator training requirements, safety features, maintenance needs, and any applicable standards or regulations.

 the purpose for which the plant was designed or manufactured

 the results of calculations, analysis, testing or examination carried out to determine that the plant, so far as is reasonably practicable, is without risk to health and safety

 conditions necessary for the safe use of the plant, and

 alterations or modifications made to the plant

Before purchasing, hiring or leasing plant you should also determine:

 the hazards and risks associated with installation, commissioning, operation, inspection, maintenance, repair, transport, storage and dismantling of the plant

 control measures needed to minimise these hazards and risks

 the manufacturer’s recommendations for the frequency and type of inspection and maintenance needed

 special skills required for people who operate the plant or carry out inspection and maintenance, including preventative maintenance

 special conditions or equipment required to protect the health and safety of people carrying out activities For example, installation, operation and maintenance, and

 alterations or modifications to be made to the plant

You should check whether the plant includes some or all of the following controls:

 contact with or access to dangerous parts is prevented For example, by using guards and protective structures

 it is of sturdy construction and has tamper-proof design

 there are no obstructions to the plant operator

 it has fail-safe operation

 it is easy to inspect and maintain

 it does not introduce other hazards, for example manual handling problems or excessive noise, into your workplace, and

 it incorporates measures to minimise risks during use, for example low noise

Duties of suppliers and purchasers of second-hand plant

Duties of persons conducting businesses or undertakings that supply plant, substances or structures

Information to be obtained and provided by supplier

Supply of second-hand plant—duties of supplier

Second-hand plant to be used for scrap or spare parts

Suppliers’ duties apply whether the plant is new, second-hand or hired out There are also some additional duties that apply when the plant is second-hand Some examples of suppliers of second-hand plant include a person conducting a business or undertaking (PCBU) who:

 sells second-hand plant at a retail outlet or directly sells their own second-hand plant

 imports second-hand plant for on-sale, and

 auctions second-hand plant, excepting certain clearing sales (see below)

 take all reasonable steps to obtain the information required to be provided by the manufacturer under sections 23(4)(a), (b) and (c) of the WHS Act, and

 when the plant is supplied, ensure the person to whom the plant is supplied is given the information obtained by the supplier

A supplier of second-hand plant must ensure, so far as is reasonably practicable, that any faults in the plant are identified

Before plant is supplied, the supplier of second-hand plant must ensure that the person to whom the plant is supplied is given written notice:

 of the condition of the plant

 of any faults identified, and

 if appropriate, that the plant should not be used until the faults are rectified

A supply of a thing does not include the supply of a thing by a person who does not control the supply and has no authority to make decisions about the supply, for example an auctioneer without possession of the thing or a real estate agent acting in their capacity as a real estate agent

Suppliers’ duties apply to a PCBU whether the sale is a one-off sale or forms part of the business’s day-to-day operations

Duty to supply safe plant

Second-hand plant suppliers must, so far as is reasonably practicable, ensure that the equipment poses no health or safety risks to anyone at or near the workplace They must also, to the extent reasonably practicable, identify faults in the plant to prevent hazards and maintain safe operation.

Suppliers of second-hand plant, other than scrap or spare parts, must give written notice to a person to whom the plant is supplied stating:

 the condition of the plant, including identified faults, and

 if appropriate, that the plant should not be used until the faults are rectified

Suppliers of second-hand plant must take all reasonable steps to obtain from the manufacturer or original supplier the information needed to use the plant correctly and safely They must also provide the buyer with the relevant documentation and guidance, including operating instructions, safety precautions, maintenance information, and any other material necessary to ensure proper and safe use of the plant.

 all available records of the plant kept by the previous owner

The information may include data sheets, test certificates, operations and service manuals, reports and a safety manual

Out-dated or non-existent safety features of second-hand plant

Second-hand plant is more likely to have out-dated or missing safety features

In these circumstances suppliers of second-hand plant must do what is reasonably practicable to supply equipment safe for use at work

The degree of risk posed by the plant must be weighed up against the cost of implementing measures to minimise it Suppliers of second-hand plant should consider:

 if it is reasonably practicable to retrofit or modify the plant to improve its safety having regard to improvements to that type of plant since its manufacture

Buyers should be provided with clear, essential information about the plant, including the purpose for which it was designed or manufactured and the conditions necessary to ensure it presents no health or safety risks when properly used This information should cover the intended use, any operating limits, and the safety precautions required to maintain safe operation, helping buyers assess suitability, ensure compliance, and prevent misuse.

 their duty to ensure the plant is safe and has all the required safety features before bringing it into service

Adequate information to be provided about the condition of second-hand plant

Adequate information must be given to the buyer about the purpose for which the plant was designed or manufactured and conditions necessary to ensure its safe use

Information about using second-hand plant safely, including its condition, may be obtained from:

 the previous owner of the plant, or

 a ‘competent person’ engaged to assess the plant and develop this information

Without this kind of information, suppliers of second-hand plant have no way of knowing whether they have met their suppliers’ duties under the WHS Act

Suppliers’ duties and agents or auctioneers selling used plant at clearing sales

Suppliers’ duties apply to sellers’ agents like auctioneers, unless the agent does not take control of the supply and has no authority to make decisions about the supply

At clearing sales, agents who sell used plants generally do not take possession of the plants and have no authority to determine supply, so they are not considered suppliers.

In these limited circumstances the suppliers’ duties will only apply to the seller—not

Supplying scrap and spare parts

Plants sold for scrap or as spare parts are generally not intended for use in a workplace, and as a result they are not typically supplied with safety documentation or operating instructions.

The supplier must clearly inform prospective buyers that the plant is being supplied only for scrap or spare parts and cannot be safely used in its current form for any other purpose This disclosure must be provided in writing or by visibly marking the item of plant.

When you hire plant, you and the supplier must, so far as is reasonably practicable, ensure that the equipment is safe to use While the plant is in your possession, you have control over how it is used in the workplace.

Before hiring a plant, assess its suitability for the intended use and verify that it has been inspected and maintained by the supplier in accordance with the manufacturer’s specifications This verification should include reviewing the logbook or maintenance manual for up-to-date service records Additionally, ensure the supplier provides the manufacturer’s information about the plant’s proper use and intended purpose so you can operate it safely and in line with official guidelines.

As a plant hire supplier or the person with management or control of plant, you have safety responsibilities when you hire or lease equipment to others You must ensure, so far as is reasonably practicable, that the plant is safe to use and properly maintained, and you must provide clear operating instructions and safety information with the plant to guide safe use.

Typically, the supplier is responsible for inspecting and maintaining the plant, but for an extended lease you and the supplier should establish arrangements to ensure the plant is consistently inspected and maintained throughout the term These arrangements may include the supplier coming to your workplace to perform maintenance, or you taking on maintenance duties while the plant is located at your site.

Lease arrangements depend on your ability to inspect and maintain the plant in line with the manufacturer’s specifications If you opt to maintain the plant yourself during the lease, you must keep thorough maintenance records and provide all relevant information and documentation to the hirer at the end of the lease.

Installation and commissioning of plant

Control of risks arising from installation or commissioning

A person with management or control of plant at a workplace must:

 not commission the plant unless the person has established that the plant is, so far as reasonably practicable, without risks to the health and safety of any person

Decommissioning and dismantling of the plant should only occur when the process can be performed, to the extent reasonably practicable, without posing risks to the health and safety of any person.

Ensure that any person who installs, assembles, constructs, commissions, decommissions, or dismantles the plant is competent and supplied with all information necessary to minimise risks to health and safety, including clear safety procedures, hazard awareness, and access to relevant documentation, and that they receive appropriate training and supervision to carry out these activities safely.

Effective risk management for plant projects requires that all stages—installation, construction, commissioning, decommissioning and dismantling—include scheduled inspections that monitor and control the risks inherent to these activities, as far as reasonably practicable.

 plant is erected or installed having regard to the manufacturer’s instructions including ensuring specialised tools, jigs and appliances necessary to minimise risk of injury during installation are used

 entry to and exit from plant complies with relevant standards

 plant is stable during installation

 the interaction of plant with people, work processes and other plant is considered

 environmental factors affecting installation and use, for example wet conditions, are considered, and

 electrical installations associated with plant comply with AS/NZS 3000, also known as the Australian/New Zealand Wiring Rules, as far as is relevant

The installer should notify the designer, manufacturer, supplier and person with management or control of plant of new risks identified during the plant installation

Positioning plant in the workplace

Plant should be positioned so:

 risks from hot plant, for example, friction, molten material, hot gases, are controlled through restricted access, guarding or insulation

 there is sufficient space (suggested 600 mm, the minimum width of a walkway) for safe access to the plant for operation, cleaning, maintenance, inspection and emergency evacuation

 the plant does not obstruct doorways and emergency exits

 the proximity to other plant does not have a negative effect on operation of the plant or work processes

 the plant rests on a suitable foundation where required, for example on a floor or other support that ensures the plant is stable and secure

 ventilation can deal with the nature and volume of emissions from the plant, and

To protect workers and others, ensure that noise exposure remains below the standard for noise under the WHS Regulation Consider noise-control measures such as locating plant in areas with sound insulation or mounting equipment to reduce reverberation, which will lower noise levels and help maintain compliance with the exposure standard.

Commissioning plant involves performing the necessary adjustments, tests and inspections to ensure plant is in full working order to specified requirements before the plant is used Commissioning includes recommissioning

The person who commissions plant should ensure:

 the commissioning sequence is in accordance with the design specifications, and

 tests are carried out to check the plant will perform within the design specifications.

Using plant in the workplace

Preventing unauthorised alterations to or interference with plant

Proper use of plant and controls

A person with management or control of plant at a workplace must:

 so far as is reasonably practicable, prevent alterations to or interference with the plant that they have not authorised

Take all reasonable steps to ensure the plant is used only for the purpose for which it is designed, and, if there is a proposed use outside its design, conduct a risk assessment to determine whether that use would increase health and safety risks Only permit the proposed use if the assessment confirms no additional risk to health and safety.

When determining whether the proposed use of plant increases health and safety risks, ensure that the risk associated with the proposed use is assessed by a competent person, and that the assessment findings are documented and used to implement appropriate safety measures.

 take all reasonable steps to ensure that all safety features, warning devices, guarding, operational controls, emergency stops are used in accordance with instructions and information that they have provided

Plant operators must be competent or closely supervised during training to prevent risks to themselves and others All operating manuals and manufacturer‑provided instructional materials should be retained on site to ensure correct operation and ongoing maintenance of the plant in the workplace The person in control of the plant should identify and address potential risks arising from operation, usage, and maintenance, and implement appropriate risk‑management measures to keep the workplace safe.

 operator fitness for work, such as fatigue

 carrying out routine or repetitive tasks, and

 local conditions and working procedures

Plant that lifts or suspends loads

Exception—Plant not specifically designed to lift or suspend a person

When equipment is used to lift or suspend people and there is no reasonably practicable option to use equipment specifically designed for lifting or suspending them, the person with management or control of the equipment must implement appropriate safety measures to manage the risks, including performing a risk assessment, selecting suitable lifting gear, ensuring proper maintenance and inspection, providing adequate training and supervision for operators, and establishing clear procedures for emergencies and rescue in line with applicable safety regulations.

 the plant does not cause a greater risk to health and safety than if specifically designed plant were used

 the persons are lifted or suspended in a work box that is securely attached to the plant

 the persons in the work box remain substantially within the workbox while they are being lifted or suspended

 a safety harness is worn if there is a risk of a worker falling from a height, and

 means are provided by which the persons being lifted or suspended can safely exit from the plant in the event of a failure in its normal operation

Evidence of licence—duty of person conducting business or undertaking

As a PCBU, you must not direct or permit a worker to carry out high risk work that requires a high risk work licence unless you have written evidence that the worker holds the relevant licence for that work.

Certain types of work, including operating industrial trucks and various cranes or scaffold and rigging activities, require a high risk work licence before the plant can be operated or the work undertaken Schedule 3 of the WHS Regulation details the classes of high risk work licences and the types of plant involved, while Schedule 4 defines the competency requirements for obtaining a high risk work licence.

Making changes

Whenever the person with management or control of the plant intends to alter the plant’s design, change how the plant is used, or modify a work system associated with the plant, they should re-run the risk management process to identify new hazards, assess the risks, and implement appropriate mitigation measures before proceeding.

When the person responsible for managing or controlling plant intends to repurpose it for a use different from its original design, they must ensure a competent person conducts a risk assessment for the new use For example, if a machine designed to cut wood is used to cut metal, all hazards associated with the new application must be identified and the appropriate controls implemented.

The competent person’s assessment should:

 include all aspects of the proposed task

 outline the reasons a purpose-designed item of plant cannot be used for the proposed task For example, the impracticability of using it

 take into account the recommendations of the designer, manufacturer or supplier of the plant and ensure the proposed use is not outside its capabilities

Identify the differences between a generic item of plant and a purpose-designed machine built for the specific task, and describe the risk-control measures that the purpose-designed plant is intended to implement to reduce the hazards it was designed to address Assess compatibility with the work, including performance, safety features, and maintenance requirements, to ensure the equipment meets task-specific safety and efficiency needs Explain how built-in safeguards, guarding, interlocks, emergency stop devices, ergonomic design, and accessible maintenance contribute to risk reduction, and outline the methods for monitoring and validating these controls, including inspections, testing, and compliance with relevant standards.

 amend relevant documentation For example, operator and maintenance manuals and signage

If a competent person decides the plant is not suitable for the proposed task, it must not be used for that task

Anyone with management or control of a plant must consult the original plant designer and manufacturer before making any alterations to ensure all safety issues are considered If the original designer and manufacturer are involved in the alteration design, the obligations under the WHS Regulation continue to apply If the person with management or control makes the alterations themselves, they become a designer or manufacturer for those changes, and those WHS obligations apply to them as well.

If the original designer or manufacturer cannot be contacted about an older or imported plant, any necessary alterations should be carried out by a competent person in accordance with the relevant technical standards, with Appendix D providing examples of published technical standards.

If the plant is subject to design registration requirements, the altered design must be registered if the alteration may affect health and safety

Plant should be isolated from power sources and be unable to be switched on or activated accidentally before alterations begin or while alterations are being carried out

Before returning altered plant to service you should:

Implement robust control measures to eliminate the risks created by the alteration; where elimination is not reasonably practicable, take steps to minimize those risks This includes providing clear information and training for both users and supervisors about the changes to ensure safe and compliant operation.

 inspect and test the plant, having regard to the altered design specifications and relevant technical standards.

Inspecting plant

Maintenance and inspection of plant

The person with management or control of plant at a workplace must ensure that maintenance, inspection and, if necessary, testing of plant is carried out by a competent person

The maintenance, inspection and testing must be carried out:

 in accordance with the manufacturer’s recommendations, if any

 if there are no manufacturer’s recommendations, in accordance with the recommendations of a competent person, or

 in relation to inspection, if it is not reasonably practicable to comply with the above, annually

Plant inspection should be conducted in accordance with a regular maintenance system to identify:

 potential problems not anticipated during plant design or task analysis

 deficiencies in plant or the equipment associated with use of the plant, for example wear and tear, corrosion and damaged plant parts

 adverse effects of changes in processes or materials associated with plant, and

 inadequacies in control measures that have been previously implemented

Inspecting associated work processes should be conducted regularly to identify:

 unsafe work practices associated with the use of plant

 negative effects of changes in processes or materials associated with plant, and

 inadequacies in control measures that have been previously implemented

Regularly inspect hand-held powered plant and repair or replace when necessary, and replace damaged or worn parts, for example grinding wheels

Control measures implemented, for example guards and warning devices, must be regularly inspected and tested to ensure they remain effective

You should keep an up-to-date register of the items of plant requiring regular inspection and maintenance It should include information on:

 allocated responsibilities for people dealing with inspections

 standards against which plant should be inspected

 critical safety instructions to be followed during inspection For example, the isolation procedure

 the procedures for particular types of inspections including:

 repaired or modified plant, and

 variations from normal operation or dangerous occurrences and trends that may be occurring

Reasonably practicable control measures must be implemented to protect the health and safety of the person conducting the inspection For example, ensure the plant is switched off and isolated from the energy source to prevent accidental re-energisation of dangerous parts, thereby reducing risk during inspection.

Guards that are removed must be replaced correctly to prevent access to the hazardous part of the plant when it is returned to use.

Maintenance, repair and cleaning of plant

All plant equipment must be maintained and repaired in accordance with the manufacturer’s specifications If you identify deficiencies in the specifications, contact the manufacturer for guidance In the absence of manufacturer specifications, plant energy sources should be maintained in accordance with the recommendations of a competent person For example, ensure fluid levels and pressures are correct and verify that brakes are functioning properly.

Plant should usually be isolated before maintenance or cleaning starts

Isolated or disengaged plant should:

 not hinder or interfere with other plant operation

 have guards in place where a risk of injury is identified, and

Establish a formal communication and consultation process with all affected workers and other persons conducting a business or undertaking to prevent health and safety risks when restarting plant operations after a shutdown for inspection, maintenance, or cleaning This process should clearly define roles and responsibilities, specify who must be informed, and ensure timely input from workers and PCBUs so concerns are addressed before restart It should also incorporate hazard identification, risk assessment, and verification steps to confirm that all safety controls—such as lockout/tagout, isolation procedures, permits-to-work, and restart checks—are in place and that personnel are trained and informed about the restart plan and associated risks.

Where plant isolation is not possible, implement robust measures to prevent accidental startup and operation Maintenance and cleaning must be conducted under controlled procedures that protect the health and safety of the worker performing the task.

If plant needs to be operated while being maintained or cleaned, the person with management or control of the plant must ensure that the operator’s controls:

 permit operation of the plant while a person is undertaking maintenance of cleaning of the plant

 while the plant is being maintained or cleaned, either:

 cannot be operated by a person other than the person carrying out the maintenance or cleaning of the plant, or

When the plant must be operated by someone other than the person carrying out maintenance or cleaning, operation is restricted to an individual who has been explicitly authorized by the person with management or control of the plant for that specific purpose.

 allow the plant to be operated in such a way that eliminates risks or, if that is not reasonably practicable, minimises the risks so far as reasonably practicable

Following maintenance or cleaning, all guarding must be replaced before plant is used

Plant with damage that poses a risk to health and safety should be withdrawn from service until those risks have been controlled.

Storing plant

At a workplace, the person who manages or controls plant must, to the extent reasonably practicable, ensure that unused equipment is left in a safe condition and does not pose health or safety risks to anyone on-site.

Plant not in use should be stored so it does not create a risk to workers or others in the workplace When plant is placed in storage, ensure it is kept out of walkways, secured against accidental movement, checked for hazards, and stored in a designated area that is organized, clearly labeled, and maintained to support safe retrieval and use.

 ensure relevant health and safety information supplied by the designer or manufacturer is provided to the person who is to dismantle or store the plant

To protect people during storage, implement control measures that eliminate health and safety risks whenever feasible, or minimise them when elimination is not reasonably practicable Examples include releasing stored energy, lowering moving parts that could descend under gravity, and providing stabilising supports to prevent toppling.

Implement robust control measures to eliminate or, where this is not reasonably practicable, minimise the risks of damage to plant during storage; these risks often arise from corrosion caused by residues of hazardous substances and deteriorating consumables, so storage practices should focus on preventing exposure, controlling residue buildup, and ensuring timely replacement of affected items.

When a plant has been in extended storage, it should be recommissioned prior to use, undergoing the same level of testing and inspection that was performed during initial commissioning.

An offline plant refers to equipment that is not currently in use but remains fully functional For example, a welding-line robot may be taken offline due to a product design modification that no longer requires its operation for that product While idle, the robot must not present a health or safety risk This is achieved by isolating the workstation from the power supply, applying lock-out and tag-out (LOTO) procedures, and providing physical stops to prevent movement if the plant is accidentally powered Further information on isolating energy sources is provided in section 4.5 of this Code.

Powered mobile plant—general control of risk

Powered mobile plant—specific control measures

The person with management or control of powered mobile plant must manage risks to health and safety associated with the following:

 things falling on the operator of the plant

 the operator being ejected from the plant

 the plant colliding with any person or thing, and

 mechanical failure of pressurised elements of plant that may release fluids that pose a risk to health and safety

Anyone who manages or controls powered mobile plant at a workplace must, as far as reasonably practicable, ensure that a suitable combination of operator protective devices is provided, maintained, and used to protect operators and enhance workplace safety.

Powered mobile plant may pose a health and safety risk if measures are not taken to prevent the plant from moving unaided—for example, rolling down a sloping surface—and to prevent unauthorised operation; unattended industrial lift trucks at the end of or during a shift are a common source of risk The person with management or control should ensure the operator understands the required safety procedures when leaving the industrial lift truck unattended These procedures include parking on a firm, level surface, applying the handbrake, switching off the motor, and rendering the lift truck inoperable, for example by removing the key.

Decommissioning, dismantling and disposing of plant

Control of risks arising from installation or commissioning

Section 3.2 of this Code provides an outline of obligations imposed on persons with management or control of plant in relation to controlling risks arising from installing and commissioning plant

Any person who has management or control of plant at a workplace must apply the same hazard-identification procedures to the decommissioning and dismantling process, including risks such as exposure to hazardous substances The plant should be dismantled in accordance with the designer's and manufacturer's instructions.

Disposal options for a plant include reselling (in whole or part), scrapping, waste disposal, or recycling If the plant is resold, the seller assumes the duties of the supplier to the purchaser and must ensure the plant is safe to load, transport, unload, and store The seller should provide complete information about the plant’s design, registration, installation, operation, and maintenance to the reseller or buyer, ensuring a smooth transfer of ownership and compliance with safety and regulatory requirements.

Suppliers must ensure, as far as reasonably practicable, that any plant they import or supply is free from risks to the health and safety of people at or near a workplace This involves conducting risk assessments, implementing appropriate safety controls, and verifying compliance with applicable health and safety regulations before the plant is delivered By prioritizing hazard identification, mitigation measures, and ongoing monitoring, suppliers protect workers and others in the vicinity from harm.

When a plant is slated for scrapping, consult your local recycling or waste-disposal authorities to ensure the equipment is made safe for loading, transportation, unloading and disposal Doing so helps minimize risk, ensures regulatory compliance, and supports safe handling throughout the scrapping process.

When supplying a plant for scrap or spare parts, clearly inform the recipient in writing that the plant is being supplied as scrap or spare parts and must not be used as a functioning plant in its current form This notice should be provided in writing or by clearly marking the item to reflect its scrap or spare-parts status.

Specific control measures

Plant registration

Keeping records

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