Automotive Workshops: Work Health and Safety Guidelines

Automotive
workshops
Work health and safety
guidelines Supported by
information advice support
SafeWork SA has forged an important partnership with a range of
organisations representing South Australia’s automotive
workshops.
We share a common purpose – keeping workers safe and helping
employers in this industry sector achieve positive safety outcomes
in line with current work health and safety laws.
would not have been
The collaborative possible of
production without feedback
this guide
SafeWork SA thanks the following
and support from a range of industry stakeholders
organisations for their involvement in and
and
support of this initiative:
technical specialists.
• Apprentice Employment Network South
They have helped create a work health and Australia (previously Group Training Australia
safety management resource that is relevant to SA)
the hazards and risks common within the
• Australian Workers’ Union
automotive workshop industry, and is adaptable to
suit the nature, size and complexity of businesses • Business SA
across South Australia. • Consumer and Business Services (Attorney
General’s Department)
• Motor Trade Association SA
• RAA
• WorkSafe Victoria, for use of their guidance
material as a base source of information.
Contents
Using this guide ............................................................ Wellbeing, psychological and physical health ..........
3 63
Simple steps to safety ................................................... Alcohol and drugs .......................................................64
4 Bullying ....................................................................... 65
Other responsibilities.................................................... 6 Fatigue ........................................................................66
Hierarchy of risk control .............................................6 Health and wellbeing .................................................. 67
Further information ...................................................... Smoking ...................................................................... 69
8
Work-related stress ..................................................... 70
Ask our advisors for help ...........................................8
Work-related violence ................................................. 71
Hazardous manual tasks .............................................
Proformas
13
Work Health and Safety Policy .................................... 75
Manual tasks .............................................................. 14
Record of Safety Discussions ...................................... 77
Wheel and tyre fitting ................................................. 15
Hazard List and Risk Assessment ................................ 79
Working inside vehicle cabins ...................................... 16
Risk Control Plan ........................................................ 81
Working under bonnets .............................................. 16
Induction Checklist .................................................... 83
Working under vehicles ............................................... 17
Training Plan .............................................................. 85
Machinery and equipment .......................................... Training Record .......................................................... 87
21 Incident /Hazard Report .............................................. 89
Angle grinders ............................................................ 22 Hazardous Substance Register .................................... 91
Compressors and compressed gases ........................... 23 Confined Space Entry Permit ...................................... 93
Electrical ..................................................................... 24 Contractor Safety Management ................................. 97
Guarding .................................................................... 25
Noise .......................................................................... 26
Vehicle hoists .............................................................. 27
Vehicle jacks................................................................ 28
Vehicle ramps and stands ............................................ 29
Welding ...................................................................... 30
Slips, trips and falls ......................................................

35
Floors, walkways, stairs and landings .......................... 36
Ladders ....................................................................... 37
Service pits ................................................................. 38
Storage and racking .................................................... 39
Traffic
management .....................................................43
Forklifts ......................................................................44
Movement of vehicles ................................................. 45
Roadside maintenance ................................................46
Hazardous
substances .................................................49
Asbestos ..................................................................... 50
Batteries ..................................................................... 51
Confined spaces ......................................................... 52
Dusts, fumes and gases ............................................... 53
Fire and explosion .......................................................54
Hazardous chemicals ................................................... 55
Spray painting and powder coating ............................. 57
1
As a Person Conducting a Business or
Undertaking (PCBU) one of your key
responsibilities is ensuring that
nobody’s health and safety is put at
risk by what your business does, what
your workers do or the work that is
done at your workplace.
This includes anyone who carries Some of the workplace safety
out work for you on a full- hazards related to automotive
time, part-time or casual basis, workshops are obvious, such as
apprentices and trainees, labour vehicles falling from hoists or
hire workers, contractors, jacks, moving vehicles or tyres
volunteers and students exploding during inflation.
participating in a school-based
Other risks are less obvious,
work experience program.
such as the long-term effects of
Workers have responsibilities exposure to asbestos fibres or
too fumes from solvents and
– to take reasonable care of their paints.
own safety and ensure they
don’t impact on the health and Injury statistics show that motor
mechanics and car detailers
safety of fellow workers,
customers or visitors. They must (spray painting and powder
also comply with reasonable coating) are also at high risk
from muscular stress injury to
instructions
their back, shoulders or knees,
and co-operate with any work
health and safety policies with a large proportion of these
and procedures that are in injuries resulting from manual
place. handling or slipping, tripping
and falling.
And in many workplaces new

and young workers, including
apprentices, are at greater risk
of injury or death due to their
lack of experience, maturity
and awareness.
2
Breaking the workplace injury chain at Finding solutions
an early stage is achievable, through Finding safety solutions can be as simple as asking your
effective work health and safety workers for their ideas – that’s consultation at its best.
management, strong leadership and a Look at what others are doing well, ask for help
commitment from everyone to make from an industry association or group, get
work as safe as it can be. information from suppliers or manufacturers, or
check relevant Codes of Practice and Australian
SafeWork SA is focused on improving safety in
South Australian workplaces and minimising the Standards.
risk of worker injury. We do this through active Safe behaviours should not be seen as the main
involvement and engagement with particular means of injury prevention. Safety solutions that
industry sectors, and by providing information, rely on administrative controls such as procedures,
advice and support. training, high levels of supervision and monitoring
for success need effort and attention to maintain
We want to help you take the guesswork out of
what's expected when it comes to work health and them.
safety standards. This guide is designed to help you Engineering, design and physical changes, such as
do that. an improved workplace layout and similar
permanent control measures, are much more
Using this guide effective and sustainable solutions.
This guide will help you understand your work Search widely for solutions and challenge both
health and safety responsibilities and the yourself and your workers about the way you all
importance of safety in your business. work together.
Start out by reading the Simple steps to safety

section on pages 4-5. Delve a little deeper into these
steps by completing the quick safety scans at the end
of this first section to see how you currently rate on
these basic aspects of setting up a safe workplace.
The following tabbed sections cover some of the

most common risks faced by automotive workshops
and provide practical safety solutions and tips for
compliance. Each section also has
a set of quick safety scans to help you measure
(self audit) how well you are currently doing and
identify areas for improvement. Select those that are
relevant to the nature, size and complexity of Business benefits
your business. Those items where you tick
‘Sometimes’ or ‘Never’ will need action to fix or Businesses that put effective work health
improve. and safety management solutions in place
can benefit from:
The final section contains proformas for forms and
records you might commonly need to document
• increased productivity
what you are doing to set up, maintain and improve • less down time caused by safety
your work health and safety practices. These are issues and injury-related absenteeism
sample documents to get you started. Personalise and
• increased morale and teamwork
tailor them to suit your particular business needs and
operations. • avoiding injury-related costs
• avoiding legal action or penalties for
non-compliance.
3
Simple steps to safety Managing hazards
You can go about setting up your safe workplace by Managing hazards should be a
following these simple steps. continuous improvement
process that finds problems
(identify hazards), gathers information about
Getting started them (assess the risks) and solves them (control
Successful safety cultures are the risks).
led from the top, where your
Use the hierarchy of control approach (refer to
actions and attitudes send a
pages 6-7) to help you mitigate the risks.
message to the people who work in your
business that you care about and are serious
Level 1 is the most effective control measure and
about their health and safety. level 3 the least effective. A combination of all the
Commit to work health and safety by defining your hierarchy control measures can be used.
own responsibilities and those of your workers, team Identify all hazards/tasks that can pose a risk to the
leaders and supervisors. Provide the necessary resources people who work in or for your business as well as
to meet those responsibilities. your customers and visitors. Take action to control
A simple written work health and safety policy, the risks. Develop simple and safe work procedures
developed in consultation with your workers, will go detailing how this is done.
a long way towards achieving this. A sample
Work Health and Safety Policy can be found A sample Hazard List and Risk Assessment and
on on page 75 – this is a sample document for you Risk Control Plan and can be found on pages 79-
to personalise and tailor to suit your particular 81. These are sample documents for you to
business needs and operations. Your policy should: personalise and tailor to suit your particular
• note everyone’s duties and responsibilities business needs and operations.
• state a commitment to improving work health

Informing , training
and safety, and how best to achieve a safe
workplace and supervising
• be dated and signed, displayed at the workplace and Provide workers with easy to
accessible to workers understand information and training
about particular job hazards
• be regularly reviewed.
and how to work safely. Provide appropriate
supervision to ensure that what’s taught at
Talking with your team training is being followed.
Involve the people who work in
Make sure that workers who are new to your
your business to identify and business are correctly inducted and adequately
resolve health and safety issues. supervised.
Effective consultation also encourages greater A sample Induction Checklist can be found on
awareness of issues and can lead to an improved page 73. A sample Training Plan and Training
safety culture and outcomes. Consultation can be Record can be found on pages 85-87. These are
through informal toolbox talks or organised sample documents for you to personalise and tailor
committees, while general safety information can be to suit your particular business needs and
provided through notice boards and signage. operations.
Use the sample Record of Safety Discussions on
page 77 to help note what has been talked about and
actions taken.
4
Maintain a safe Record keeping
workplace Document what you’re doing
Once safe systems and to maintain and improve your
procedures are in place, they work health and safety. Keeping
need to be maintained through an ongoing records will help you to monitor the health
and safety performance of your business as well
focus on health and safety.
as meet your legal requirements.
Maintain a safe workplace by:
You will need to keep the following records:
• carrying out regular workplace inspections
• all incident/hazard reports
• ensuring equipment and tools are safe to use and
• hazardous chemicals and asbestos registers (if
maintained
those substances are in your workplace)
• fixing high risks immediately and others as soon as
• plant registration documents
possible in order of level of risk
• tests, maintenance, inspection and repairs for
• discussing common injuries, work practices and
specific items of plant.
procedures with workers
• keeping up-to-date knowledge of product labels, It’s also useful to keep records of:
Safety Data Sheets and manufacturer’s instruction • hazard identification, risk assessment and
manuals control processes
• having an easy to use hazard, near miss and • maintenance of all items of plant and
injury reporting process as well as reviewing equipment
incident reports
• workers’ induction and training.
• planning and regularly testing of emergency
A sample Incident/Hazard Report can be found
procedures (e.g. for fire, medical, chemical leaks)
on page 89 and a sample Hazardous Substance
• keeping workers informed of any changes, and Register on page 91. These are sample documents for
providing training opportunities when anything you to personalise and tailor to suit your particular
new at work is introduced. business needs and operations.
Monitoring and reviewing

to improve
Managing and improving health
and safety needs to be
an ongoing process.
Safety processes and operations evolve with time,
and workers and equipment come and go, changing
the risks in your workplace.
Having followed these steps and established the ways

you will work safely (known as your safety systems),
you should regularly review and monitor how
effective they are, as well as make any necessary
adjustments to keep them
up-to-date and continually improve.
5
Other responsibilities Hierarchy of risk control
Your work health and safety responsibilities also The ways of controlling risks are ranked from the
include the following: highest level of protection and reliability to the
lowest as shown in diagram on page 7. This
Fire and emergency procedures
ranking is known as the hierarchy of risk control.
Develop fire and emergency procedures (e.g.
fire extinguishers, alarms, emergency You must always aim to eliminate a hazard, which
contacts), evacuation plans, and testing of is the most effective control. If this is not
procedures and plans. reasonably practicable, you must minimise risks by
working through the other levels in the hierarchy.
First aid
Determine first aid requirements (e.g. first aid kits, Level 1 control measures
people trained to administer first aid). The most effective control measure involves
eliminating the hazard and associated risk. The
Work environment and facilities best ways to do this are by either removing the
Ensure tools and equipment are safe to use and are hazard completely (e.g. getting rid of trip
maintained and regularly serviced. hazards, disposing of unwanted chemicals), or not
introducing the hazard into the workplace in the first
Supply workers with appropriate safety gear,
place (e.g. work at ground level, not at height, to
where necessary.
eliminate the risk of a fall).
Provide facilities for workers (e.g. toilets, drinking
Eliminating hazards is often cheaper and more practical
water, washing and dining areas, shelter).
to achieve at the design or planning stage of a product,
Provide and maintain a physical work environment process or place used for work.
free of heath and safety risks (e.g. workspace, lighting,
In these early phases, there is greater scope to design
ventilation).
out hazards or incorporate risk control measures that
Ensure workers do not eat food in the workshop are compatible with the original design and
area (e.g. provide a separate dining area). functional requirements. For example, a noisy
machine could be designed and built to produce as
little noise as possible, which is more effective
than providing workers with personal hearing
protection.
It may not be possible to eliminate a hazard if

doing so means that you cannot make the end
6
loads, place guards around moving parts of
machinery, install residual current devices).
product or deliver the service. If this is the case,
eliminate as many of the risks associated with the Level 3 control measures
hazard as possible. These control measures do nothing to control the
hazard at the source, relying instead on human
Level 2 control measures
behaviour and supervision. Used on their own, they
If it is not reasonably practicable to eliminate the tend to be least effective in minimising risks.
hazards and associated risks, you should minimise
them using one or more of the following: Two approaches to reducing risk in this way are:
• Substitute the hazard with something safer • administrative controls – work methods or
(e.g. replace noisy machinery with quieter procedures designed to minimise hazard exposure
models). (e.g. develop procedures on how to operate
machinery safely, limit exposure time to a
• Isolate the hazard from people – physically separate
hazardous task, use hazard warning signs)
people from the source of harm by distance or
using barriers (e.g. install guard rails around service • personal protective equipment (PPE) – which
pits, store chemicals in a fume cabinet). limit exposure to the harmful effects of a hazard,
but only if worn and used correctly (e.g. ear
• Use engineering controls – introduce a
muffs, respirators, protective eyewear).
mechanical device or process that is physical in
nature (e.g. use trolleys or hoists to move heavy Administrative controls and PPE should be used
as a last resort when no other practical control
measures are available, as an interim measure
HIGHEST MOS
T
1 Level 1
Level of health and safety protection
Eliminate the hazards

Reliability of control measures
2
Level 2
Substitute the hazard with something safer
Isolate the hazard from people
Reduce the risks through engineering controls
3
Level 3
Reduce exposure to the hazard using
administrative controls
Use personal protective equipment
LOWEST LEAST
7
Further information Ask our advisors for help
Work health and safety laws, codes Our experienced work health and safety
of practice and Australian Standards advisors can help you by providing free
information, advice and support
You should be familiar with the Work Health
tailored to your workplace and the
and Safety Act 2012 (SA) and the Work
work you do. They have no inspector
Health and Safety Regulations 2012 (SA).
powers, so you can be comfortable
These laws protect all workers in South Australia,
asking them to help you.
including employees, contractors, subcontractors,
outworkers, apprentices and trainees, work We’d love to visit your workplace to
experience students, volunteers and employers who help you find solutions to identified
perform work. To access the full Act and hazards and risks, lead an information
Regulations, visit legislation.sa.gov.au. session or participate in toolbox
meetings or safety walks.
The following supporting Codes of Practice provide
further practical guidance on the basics of setting up a We can also help you implement
safe workplace for people responsible for managing your own safety management
risks to health and safety: system – it’s easy when you know
• Code of Practice: How to Manage Work how.
Health and Safety Risks
Call us on 1300 365 255 to book a
• Code of Practice: Work Health and Safety free advisor’s visit at a time and place
Consultation, Co-operation and Co- that suits you.
ordination
Go to
• Code of Practice: First Aid in the Workplace safework.sa.gov.au/freeadvice
• Code of Practice: Managing the for more information.
Work Environment and Facilities.
Find all the Codes at
safework.sa.gov.au/cop.
Other Codes of Practice that are specific to the

types of hazards and risks found in automotive
workshops are listed in individual sections of this
guide, as are relevant Australian Standards,
national guidance material and other useful
publications and information.
Australian Standards can be searched for and

purchased in either electronic or hard copy format
from the online shop at saiglobal.com, or
they can be borrowed for free from the
SafeWork SA Library.
Product safety recall

Subscribe to the recalls section of the Product Safety
Australia website productsafety.gov.au for daily
recall notifications. These can then be delegated to one
or two responsible workers who are tasked with
checking for and removing any recalled products
from use.
8
Quick safety scans – simple steps to safety
Use these quick safety scans to look at key work health and safety (WHS) issues in your workplace. Those items
where you tick ‘Sometimes’ or ‘Never’ will need action to fix or improve. Use the information provided earlier
in this section to help you.
Getting started Always Sometimes Never
You have a WHS policy which includes consultation, managing hazards, informing/
training/supervising, maintaining a safe workplace, monitoring and reviewing
The WHS policy is displayed and easily accessible
The WHS policy is regularly updated
Talking with your team Always Sometimes Never
Workers are encouraged to be involved as you develop and later review your work health
and safety policy and procedures
You have discussions or consult regularly with workers about health and safety issues
Records are kept of meetings, feedback, decisions and action items, and safety
solutions are regularly reviewed for effectiveness
You have procedures for resolving issues
Managing hazards Always Sometimes Never
Hazards are identified and their risks considered
Control measures are implemented for all identified hazards
Safe work procedures are developed for each work activity, with worker input
Hazard identification, risk assessment and control processes are in place
Informing, training and supervising Always Sometimes Never
You speak to workers about their training needs
A training plan is in place
Records are kept of each worker’s training
Workers are trained to follow safe work procedures and can demonstrate their ability to do
tasks safely
You supervise workers in their tasks
You have a new worker induction program/checklist
New workers are adequately supervised until they can demonstrate task competencies
There is a procedure for visitor/contractor sign-in and access to the workplace
You have an induction process if visitors/contractors will access hazardous areas
9
Maintain a safe workplace Always Sometimes Never
Regular safety checks/inspections are carried out
You have a reporting process for hazards and incidents/injuries (including near misses)
Incident reports are reviewed
Incident report forms are used
Tools and equipment are kept in good condition, and regularly serviced and maintained
All notifiable incidents are reported to SafeWork SA
Record keeping Always Sometimes Never
Induction records are kept for five years from the date of the last entry
Worker training records are kept
You maintain a hazard register
You maintain a chemical register
You maintain an asbestos register
Plant registration details are kept and easily accessible
Records are kept of testing and inspection of items of plant
Monitoring and reviewing Always Sometimes Never
You regularly review your safety processes with your workers
You investigate all incidents or near misses to identify any safety gaps in your business
10
Quick safety scans – other responsibilities
where you tick in this section ‘Sometimes’ or ‘Never’ will need action to fix or improve. Use the information
provided earlier in this section to help you.
First aid Always Sometimes Never
You have done a risk assessment to determine appropriate first aid requirements
Approved first aid kits and equipment are provided, maintained and accessible
An adequate number of people are trained to administer first aid
Eye washing facilities are provided
First aid records are kept
First aid signs are posted
Fire and emergency procedures Always Sometimes Never
Correct types of fire extinguishers are provided, located and signed appropriately
Fire extinguishers are regularly maintained
Workers are trained in fire-fighting equipment use
Fire-fighting equipment is in good condition
You have an emergency response plan and evacuation procedure in place
You have a fire alarm system and carry out system tests and emergency drills
Emergency lighting is available, visible and periodically tested
Emergency exits are clearly signposted and unobstructed
Smoke detectors are fitted, tested and maintained
Emergency contact numbers are displayed
11
Work environment and facilities Always Sometimes Never
Kitchen/lunchroom facilities are adequate and clean, well lit and well ventilated
Drinking water is available
Toilets (lockable) and showers/washing facilities/changerooms are adequate and clean (incl.
sanitary units), well lit and ventilated, well provisioned
Protective clothing is provided (and laundered, if appropriate)
Secure personal storage is provided for workers
Lighting is adequate for work-specific tasks/locations (e.g. lead lights) and in other
public areas (e.g. walkways, offices)
Lighting is clean and in good condition, and diffusers are in place
Windows are clean and unbroken
Workers are able to control incoming natural light
Ventilation is adequate for work tasks/areas (check for temperature, draughts, odours, lack of
fresh air)
Heating and/or cooling operates at a comfortable level
You have a process in place for work in extreme heat or cold
Cleaning equipment and materials are available, and floors are kept clean
Metal rubbish/waste storage bins are provided
Waste (general and hazardous) is regularly removed
Work areas and benches are tidy and uncluttered
You have a process in place for isolated or remote workers
You have an effective means of communication with isolated or remote workers (e.g.
mobile/satellite phone, UHF radio)
12
Hazardous
manual
tasks
Hazardous manual tasks
Bending, stretching and reaching movements, Equipment and devices you can use include:
static lifting and positioning tasks – either with • vacuum lifters for windscreen insertion
high, sudden, repeated or sustained force – can
• hoists when detailing
lead to stress on the body, muscle strain,
overexertion • hip-height roller conveyors and ramps to load or
and injuries. move tyres
Carrying out work at the limit of reach or in • order picking ladders with load tables for
awkward postures away from the body’s centre of stock access
gravity requires muscles to work harder. When these • pads and body tables for comfortable work in
postures are held for too long, muscular or spinal footwells and under dashes
injuries can occur.
• castors on heavy toolboxes.
Look at reducing heavy lifting or working in
sustained or awkward postures by using
Further information
mechanical aids and devices (e.g. tyre underslides,
overhead-mounted body support harnesses). Code of Practice: Hazardous Manual Tasks
safework.sa.gov.au/cop
If equipment exists to help reduce the risk of body
stressing, it should be used. You may already be using SafeWork SA’s Hazardous Manual Tasks:
tools powered by compressed air, hoists, cranes and Overview and Risk Management Worksheet can
lifting hooks, bead breakers and body underslides to be used to help you assess individual manual tasks.
get under vehicles.
safework.sa.gov.au
13
Manual tasks Safety solutions
Carry out workplace inspections and observe
manual tasks, check injury/hazard reports, and
Hazards/risks identify any relevant contributing factors
(e.g. slippery floors).
Increased weight equals increased risk: People
differ in height, weight and physical capacity, so it is Modify workplace layout and equipment where
difficult to define what is an unsafe weight for possible (e.g. automate the manual tasks, replace hand
everyone. However as a general rule, if a manual task tools with power tools).
seems difficult or strenuous, then it may present a
Use lifting aids (e.g. jigs, slings, dollies) that are
significant risk. Discomfort can be an early warning
adaptable to the size/shape of handled items (e.g.
sign, especially if it reoccurs the next day or continues
engines, transmissions).
after days off.
Deliver goods or equipment directly to the point of
The risk is not just about weight: Often
use to eliminate multiple handling.
the risk is due to a combination of weight and
posture, such as bending forward, and movements such Modify working loads (e.g. redistribute the weight, or
as holding the load away from the body or twisting, replace heavy items with lighter, smaller, more easily
as well as the shape or configuration of the load. handled items).
Manual tasks can cause gradual wear and Redesign work patterns (e.g. change the frequency and
tear to the body: Damage to the body can build type of tasks done by workers, rotate workers between
up over time. tasks).
The risk of injury is cumulative where Ensure everyone has both general and specific
repetitive movements or fixed/awkward hazardous manual task training, especially young and
postures are concerned: Regardless of how many new workers.
different tasks a worker might perform each day,
injury risk can exist if the total time spent performing Consult with workers before purchasing any new
similar postures or actions exceeds one hour. equipment and tools. Ensure they are designed for
safe use and are a best match to both the worker
Young and new workers: Workers who are and task needs.
young and still developing physical strength, and any
new worker lacking experience, are at greater risk of Provide personal protective equipment (PPE) that
injury. is:
• suitable for the nature of the work and the
hazard (e.g. workers who need to carry out
tasks in extreme heat or cold, wind or rain)
• comfortable to wear, and of a suitable size
and fit
• maintained, repaired or replaced when required
• used or worn by workers who have been
trained in its use and care.
14
Wheel and tyre fitting Safety solutions
Use vehicle hoists, wheel balancers, tyre changers
and mechanical aids.
Hazards/risks
Roll, rather than carry, tyres and wheels when
The primary risks arise from high force and moving them over a distance.
awkward postures during manual handling, rotating
Deflate tyres to minimise potential explosion
parts, nuisance dusts and asbestos (from brake
hazard.
linings), nipping and trapping points, exposure to
noise, falling vehicles, nearby traffic, compressed air Use chocks to prevent movement of vehicles when
and tyre/wheel explosion due to defective or split they are being raised or lowered vehicles on jacks.
rims.
Place wheels firmly on mountings before nuts
are done up evenly and firmly.
Visually inspect tyres and valves for

damage and wear.
Follow the manufacturer’s specifications for tyres

and rims.
Use restraining devices when inflating tyres on

split rim assemblies.
Use tyre cages when inflating tyres.
Train technicians in safe work practices and

ensure they follow them.
Provide regular training sessions in correct

manual handling practices.
Provide personal protective equipment

(PPE) that is:
hazard (e.g. eye and ear protection, high-
visibility clothing)
and fit
15
Working inside vehicle Working under bonnets
cabins
Hazards/risks
Hazards/risks Associated risks include over-reaching, awkward or
sustained postures, poor lighting and unguarded parts
Working inside the confined and awkward spaces (e.g. belts, fans).
within vehicle cabins, often for sustained periods, can
result in body-stressing injuries.
These risks can be minimised or eliminated by Safety solutions

applying practices that change the way the work is
done or better support the worker and/or the tools. Adopt working positions between shoulder and
knee, and close to the body.
Raise vehicles to approximately waist height to

remove the need to bend as far forward.
Safety solutions Ensure postures are not held for long durations
Remove seats or other items to improve access. through job rotation, using mirrors to reduce time
exploring the engine, and using purpose-built jigs.
Raise vehicles on a hoist to enable easier access
under the dash from a standing position. Provide protective pads to allow for resting of
the upper torso on vehicles being worked on (also
Change the vehicle working angle and height by prevents paintwork or panel damage).
using a lifting device (e.g. hoist) to improve access to
the work area. Use overhead-mounted body support harnesses to
reduce back strain.
Use a spacer or filler (e.g. beanbag or foam
equivalent) to fill a footwell, if it improves the Provide powered tools (e.g. air operated tools) that
working position. reduce the time spent applying force while
working at the limits of reach.
Support the tools and the worker, so that muscle
effort goes into using, not holding (e.g. use lanyards, Remove the bonnet to reduce awkward
magnetic clamps). work positions.
Use powered tools (e.g. air operated) to reduce Provide a stable step to give access to the engine
time spent working in constrained, awkward bays of taller vehicles.
postures.
Use a hoist to give access from underneath, if this
Use braces to support the load (e.g. when improves the working position.
undoing dashes).
Reduce the weight before handling (e.g. drain
Use vacuum lifters to hold and position fluids before lifting).
windscreens.
Ensure there is adequate lighting (e.g. lead lights).
Ensure there is adequate lighting (e.g. lead
lights).
16
Working under vehicles
Hazards/risks
Associated risks include poor lighting,
cramped working conditions, awkward
or sustained postures, hot engine parts and
hazardous substances (e.g. fuels, fluids).
Safety solutions
Improve the worker’s access (e.g. use of
creepers).
Improve support for the worker (e.g. use a chair

with head support that can be tilted).
Change the vehicle working angle and height by

using a lifting device (e.g. ramps or side supports) to
improve access to the work area.
Provide powered tools (e.g. air operated) that

reduce the time spent applying force while
working at the limits of reach.
Support the tools as well as the worker so that

muscle effort is reduced.
Reduce the need to hold or support parts being

removed (e.g. use dollies, slings etc).
Reduce task length for above-shoulder work

(e.g. remove entire units that can then be worked on
at a bench).
Provide differing height vehicle hoists or platforms

for workers to stand on, and use in-ground pits.
Ensure there is adequate lighting (e.g. lead lights).
Provide personal protective equipment (PPE) that is

appropriate for the nature of the work (e.g. eye and
hand protection) and of a suitable size and fit, and
ensure that it is maintained in good condition.
Further information
SafeWork SA:
• Safety Alert – Truck tipping and tilting trays
safework.sa.gov.au
17
Quick safety scans – hazardous manual tasks
where you tick ‘Sometimes’ or ‘Never’ will need action to fix or improve. Use the safety solutions suggested
earlier to help you.
Manual tasks Always Sometimes Never
Risks (e.g. handling heavy and awkward items) are identified,

assessed and controls implemented
Sustained and repetitive tasks in awkward postures are minimised
Workers can vary their posture and pace throughout tasks (e.g. do not have to stand, sit,
kneel or squat for long periods)
Workers can perform tasks in a comfortable, upright, forward facing position (not
bent or twisted)
Workers are trained in solving manual handling problems and correct

manual handling techniques
Mechanical aids (e.g. jigs, slings, dollies, chains) are used to lift or move heavy or
awkward items
Tool boxes and benches are mobile for ease of use
Safe, task-suitable hand tools are provided
Hand tool weight/comfort to hold and use is considered
Hand tools are replaced by power tools
Workers are consulted about new tools/equipment prior to purchase
Job rotation is used for repetitive tasks
Jobs are redesigned/working loads are modified
Equipment is regularly inspected, tested and tagged (where required)
Equipment is regularly maintained
Workers are protected against vibration when using powered equipment for long
periods (e.g. grinders)
18
Wheel and tyre fitting Always Sometimes Never
Vehicle hoists, wheel balancers, tyre changers and mechanical aids are used
Tyres and wheels are rolled, not carried, over distance
Tyres are deflated to minimise potential explosion hazard
Chocks are used when raising or lowering vehicles on a jack
Wheels are firmly placed on mountings before nuts are done up
Tyres and valves are visually inspected for damage and wear
Tyre inflation cages are available and used
Manufacturer’s specifications for tyres and rims are followed
Restraining devices are used when inflating tyres on split rim assemblies
Workers are trained in safe work practices for tyre assembly/fitting
Regular training sessions are conducted in correct manual handling practices
Appropriate PPE is provided and used (e.g. eye and ear protection, high-visibility
clothing)
PPE is maintained, repaired or replaced as required
Workers are trained in the correct use and care of PPE
Working inside vehicle cabins Always Sometimes Never
Adequate lighting is provided, especially lead lights
Risks from awkward and sustained working positions are identified and controlled (e.g.
footwell spacers/fillers)
Powered tools are provided, where appropriate
Braces (for undoing dashes), vacuum lifters (for windscreens) and magnetic clamps
etc are in use
Working under bonnets Always Sometimes Never
remove bonnet)
Body support harnesses are used
Protective pads are used for upper torso support
19
Working under vehicles Always Sometimes Never
creepers, tiltable chairs)
Hoists/platforms/in-ground pits are used to provide better access
Dollies/slings are used to reduce the need to hold/support parts
Operating instructions are displayed (where required)
Appropriate PPE is provided and used (e.g. eye and hand protection)
20
Machinery
and
equipment
Machinery and
equipment
People who service or repair vehicles, machinery and Chemical or thermal burns can result in significant
equipment could be at risk when: body tissue damage.
• working at height
All machinery and equipment should be regularly
• using rigging, jacks etc. to lift machinery serviced and maintained according to the
and equipment manufacturer’s instructions. All equipment
• using power tools, welders and extension leads that operators must be instructed, trained and
supervised in its safe use.
may be damaged or wet
• exposed to poor isolation of energy sources or Machinery and equipment should only be used for its
stored energy, such as spring-loaded or intended purpose.
counter-balance mechanisms, compressed air or
Moving parts of machinery can cause bruising,
fluids, or parts held in position by hydraulics or
crushing, fractures, lacerations, dislocations,
pneumatic (air) rams
amputations and even fatalities.
• placing hands close to mechanisms and being
injured if caught or trapped by moving parts Where there is a risk of injury from moving parts
or processes, guarding in the form of a physical or
• moving heavy parts or repairing failed parts other barrier must be used as a first line of
(e.g. electric motors or gear box assemblies) defence. There must also be isolation or
• disabling or removing normal safety systems to disengaging procedures in place when cleaning or
access mechanisms maintenance is performed.
• working in low light or bright directional light
• entering confined spaces Further information
• working alone or in isolation Code of Practice: Managing the Risks of Plant
in the Workplace
• exposed to excessive or sustained noise levels.
Spray booths, sanding and grinding equipment,
airless spray equipment and compressed air all
create potential hazards. Subscribe to the recalls section of the Product Safety
Australia website productsafety.gov.au for daily
recall notifications. These can then be delegated to
one or two responsible workers who are tasked with
checking for and removing any recalled products
from use.
21
Angle grinders Safety solutions
Consider whether an angle grinder is actually
the best tool to perform the task.
Hazards/risks
Ensure all grinders have fitted guards and
Angle grinders can be dangerous power tools. that these are not removed.
Kickbacks can result in severe cuts. Discs can
Ensure all workers maintain a safe distance
shatter or disintegrate, especially when thin
from grinding work in progress, and use
cutting discs are used. The fragments produced
welding screens to stop others being hit by
may cause eye injuries or become lodged in
flying particles and sparks.
other parts of the operator’s body.
Conduct grinding and cutting work well
Electrical cords can become damaged in the
away from hazardous chemicals, gases and
workshop environment, creating the risk of
spray booths.
electric shock (read about electrical safety on
page 24). Check that electrical cords are undamaged and
in a safe working condition.
Sparks and flying particles can also introduce
an ignition source where hazardous Have grinders inspected and tested by
flammable chemicals and gases are used in a competent person every 3 months (as a
close proximity. best practice recommendation).
Provide operators with training and

instruction on safe work procedures for
angle grinders.
Provide operators with personal protective

equipment (PPE) that is appropriate for the
nature of the work and of a suitable size and
fit (e.g. goggles, face shields), and ensure
that it is maintained in good condition.
Further information
SafeWork SA Safety Alert – Angle
Grinders
safework.sa.gov.au
22
Compressors and Safety solutions
compressed gases Ensure the Safety Data Sheet (SDS) for any gas in use
is available.
Store cylinders upright and restrained to prevent

Hazards/risks them falling or rolling.
Compressed and liquefied gases are in vessels under Regularly maintain regulators and valves, and keep
pressure, and are used in workshops as fuel, as a them away from contaminants (e.g. oils, greases).
source of oxygen or as a shielding gas in certain
Carry out pre-operational inspections, in particular
types of welding.
checking for leaks.
Risk factors associated with their use include
the following: Carry out inspections for rusting/pitting on
compressors at least every two years, and internal
Fire or explosion: Gas leakage is one of the greatest inspections at least every 4 years.
hazards when storing, handling and using cylinders.
An ignition source, such as a spark from an angle Train workers in the safe storage, handling and use
grinder being used nearby, could cause a fire or of compressed air and all air-operated tools and
explosion. equipment. Compressed air must never be
deliberately misused.
Asphyxiation: Dangerously low levels of oxygen
can cause fatigue and, in extreme cases death. Install compressors in an area that minimises noise.
Working in an area with inadequate ventilation can
Register air tanks and receivers (if required).
present an asphyxiation hazard. For example, gases
that are heavier than air can accumulate in pits, Drain air tanks daily to prevent rusting
while those lighter than air can accumulate in roof and pitting.
spaces and lofts/mezzanines. Read more about
working in confined spaces on page 52. Ensure PVC air lines (if used) are rated for
compressed gas.
Uncontrolled release of pressure:
A sudden release of compressed air may cause hearing Further information
damage or even rupture an ear drum. Compressed air
can also deeply penetrate the skin, resulting in an air Code of Practice: Managing Risks of
bubble in the bloodstream (an embolism). Even a Hazardous Chemicals in the Workplace
small quantity of air or other gas in the bloodstream safework.sa.gov.au/cop
can be fatal.
23
Electrica Ensure all AC power circuits are protected with
appropriately rated fuses or circuit breakers.
l
Arrange electrical leads so they are not easily
Hazards/risks damaged, and do not run across floors and
doorways or over sharp edges.
Electrical equipment that is not properly earthed or
maintained can lead to electric shock, serious burns Only use leads and tools designed for wet or
or even death. damp conditions when they must be used in
those circumstances.
Ensure powerboards used for portable equipment are

Safety solutions
RCD protected.
Substitute electrical with compressed air-operated
If any current protective device (RCD or circuit
equipment (no need for electrical testing).
breaker) is triggered, do not re-energise the
Substitute electrical with extra-low voltage system until the reason has been identified by a
equipment (e.g. 24 volt hand-held angle grinder). competent person.
Regularly conduct visual inspections and testing of

electrical equipment, including RCDs (the nature and
frequency will vary depending on the electrical
risks).
Maintain all electrical equipment in accordance

with the WHS Regulations and keep log
book records of all inspections, servicing and
maintenance.
Earth containers accordingly when solvents are

being decanted, to control static electricity.
Disconnect, or isolate, and label accordingly any

equipment identified as unsafe, and ensure it is not
reconnected until it has been repaired and tested.
Further information
Code of Practice: Managing Electrical Risks in
the Workplace
SafeWork SA Safety Alert – Isolation

procedures
safework.sa.gov.au
Australian Standard AS/NZS 3760: In-service safety

inspection and testing of electrical equipment
24
Guarding Further information
Code of Practice: Managing Risks of Plant in the
Workplace for more information on types of
Hazards/risks barriers, environmental factors, colour coding etc.
Workers who operate or maintain unguarded or
inadequately guarded machinery and equipment are Various forms of guarding and interlocking are
at risk of minor abrasions, burns or cuts, and more also described in Australian Standard AS4024.1:
severe injuries such as lacerations, crushing, fractures Safety of machinery (parts 1601 and 1602).
or even amputation. Common hazards arise from nip
points, rotating parts, noise, sparks and flying debris.
When the operation of any machine part, process or

function, or unintended contact with it, may cause
injury to workers or others in the immediate work
area, it must be guarded as a first line of defence.
Guarding in the form of a physical or other type of

barrier can:
• prevent contact with moving parts that do
not require regular adjustment
• control access to dangerous moving parts,
machines and equipment
• screen harmful emissions (e.g. radiation)
• minimise noise (use of sound-absorbing
materials)
• prevent ejected parts or off-cuts from
striking people.
Guarding must:
• be of solid construction, securely
mounted and resistant to impact
or shock
Safety solutions
• prevent by-passing or disabling of the
If guarding is used, ensure that it: guard, and disable plant operation if it
• is a permanently fixed barrier, if access to the area of is removed
plant requiring guarding is not necessary during • not create a risk in itself (e.g. it must
operation, maintenance or cleaning, or not obstruct operator visibility, weaken
• is an interlocked physical barrier, if access to the the plant, cause operator discomfort or
area requiring guarding is necessary during create new hazards such as pinch
operation, maintenance or cleaning, or points or sharp edges)
• can only be altered or removed with a tool, if it • be properly maintained, and enable
is not reasonably practicable to use either ease of servicing, maintenance
a permanently fixed or interlocked physical and repair
barrier, or • control any risk from
• includes a presence-sensing safeguarding system, if broken/ejected parts and
it is not reasonably practicable to use either a workpieces.
permanently fixed, interlocked or fixed- in-
position physical barrier.
25
Noise Safety solutions
Eliminate the noise source.
Keep noise levels below the exposure standard of

Hazards/risks
85dB(A) in an 8-hour day so that critical situations
Unwanted or damaging sounds may cause noise- can still be communicated despite noise. Refer
induced hearing loss or tinnitus (ringing in the ears). to the Code of Practice for information on work
It may also cause other health effects such as stress, shifts exceeding 8 hours.
hypersensitivity to noise, and increased blood pressure
Substitute noisy machinery with quieter models
and heart rate.
– or ‘buy quiet’ when purchasing new or
It can also interfere with communication at work, replacement equipment, which is a cost-effective
which can lead to incidents. way to control noise at the source.
The harmful effects of noise may be cumulative (e.g. Introduce engineering controls to treat noise at its
going to nightclubs may result in young people source or in its transmission path (e.g. use sound
having some early damage to their hearing before dampeners or silencers, noise barriers/partitions/
joining the workforce). screens and isolation).
Specialist skills or equipment are not needed to Introduce administrative controls to reduce the
make a preliminary assessment to identify sources of number of workers exposed to noise (e.g. training and
hazardous noise in your workplace. However, it education, job rotation, job redesign or designing
should be done in consultation with those who rosters).
understand the work processes, such as affected
Provide personal protective equipment (PPE) that
workers.
is:
Conduct a walk-through inspection of your • suitable for the nature of the work and the
workplace to help determine: hazard (e.g. earmuffs, ear plugs)
• sources of excessive, distracting or disruptive • comfortable to wear, and of a suitable size
noise (e.g. is it difficult to hear a normal voice and fit
within one metre of a noise source)
• workers likely to be exposed to excessive noise
• work activities that are noisy and may pose a trained in
If workers areitsfrequently
use and care.
required to wear PPE to
risk to hearing reduce the risk of hearing loss from noise exceeding
• ways of reducing noise levels. the exposure standard of 85dB(A), implement an
audiometric testing regime. Keep testing records.
If you are unsure about the level of exposure or how
to minimise the risks effectively, you should take
the next step to assess hearing loss risks.
Further information
Code of Practice: Managing Noise and
Preventing Hearing Loss at Work
26
Vehicle Inspect and maintain the hoist at least every 3
months.
hoists
Arrange for a comprehensive annual inspection to
Hazards/risks be carried out by an independent, qualified,
competent person.
Failure of lifting equipment can cause crush
injuries or fatalities. Undertake hoist inspections in accordance with
the manufacturer’s instructions, and with
Moving vehicles on and off hoists also presents reference to Australian Standards:
potential hazards. • AS/NZS 2550.9: Cranes – Safe use.
Part 9: Vehicle hoists
Safety solutions • AS/NZS 1418.9: Cranes (including hoists
Train operators in the safe use of hoists and ensure they and winches). Part 9: Vehicle hoists.
do not work under a suspended load without checking
that safety features are engaged and operating correctly. Ensure electrical hoists and wiring are tested with
reference to Australian Standard AS/NZS 3000:
Prominently display equipment operating and Australian Wiring Rules.
maintenance instructions, as well as the safe
working load. Record all inspections, servicing and maintenance in
a log book which is available for all users,
Ensure hoists have a valid design registration maintenance or inspection personnel.
number issued by a work health and safety
regulator in Australia.
To avoid worker entrapment, ensure that moving

parts of the hoist or its load are located at least
600mm away from any other fixed structure or
equipment that moves.
Ensure that operator controls are undamaged, clearly

marked and positioned for effective, safe use.
Check that the dropper bar (safety prop) is fitted to

any in-ground, hydraulic, ram-type hoist.
Conduct pre-operational inspections daily (e.g.

look for leaks in hydraulic and pneumatic
components).
27
Vehicle jacks
Hazards/risks
These portable devices require experience in their
placement before use to minimise risk to the
operator.
Associated risks include the sudden fall of vehicles due

to overbalancing, incorrect use of jacking points, poor
maintenance or leaking hydraulic fluid, and use of
jacks on surfaces that are not level or firm.
Safety solutions
Train operators in the correct and safe use of
the equipment, including ensuring that:
• jacks are based on a firm, level and secure
surface (preferably concrete)
• vehicle stands are used when a vehicle is raised
and wheels are chocked
• nobody remains in a vehicle that is being
jacked
• nobody places any portion of their body under a
vehicle supported by a jack.
Prominently display equipment operating and

maintenance instructions, as well as the safe
working load.
Conduct daily pre-operational equipment

inspections.
Inspect and maintain the jack at least every

3 months, in accordance with the manufacturer’s
instructions, to ensure it can be manoeuvred
effectively.
Record all inspections, servicing and maintenance in a

log book which is available for all users, maintenance
or inspection personnel.
28
Vehicle ramps and stands
Hazards/risks
Common risks arise when ramps and stands are
poorly placed, unsuitable for the work involved
(e.g. load capacity), used on unstable/uneven
surfaces, or poorly stored and maintained (creating
weaknesses).
Safety solutions
Conduct pre-operational inspections daily.
Ensure axle stands are based on a solid, level

and secure surface (preferably concrete).
Secure vehicles on ramps to prevent movement

(e.g. use of handbrake, wheel chocks etc).
Do not adjust stand heights when they are bearing

weight.
Mark ramps and stands with rated safe working

load.
Only use ramps and stands in pairs.
Slowly drive vehicles onto ramps or stands with

guidance from another person outside the vehicle.
Further information
Australian Standards:
• AS/NZS 2640: Portable ramps for vehicles
• AS/NZS 2538: Vehicle support stands
29
Welding Install non-flammable screens and partitions.
Use physical barriers and warning signs – unless

safeguards are used, entry into the welding area
Hazards/risks should not be permitted.
Welding is a potentially hazardous activity and Store cylinders upright and restrained to prevent
precautions are required to avoid electrocution, fire them falling or rolling.
and explosion, burns, electric shock, vision damage, Light up gas cylinders using a flint or piezo electric
inhalation of poisonous gases and fumes, and lighter, not matches or cigarette lighters.
exposure to intense ultraviolet radiation.
Keep all fittings and hoses away from
Radiation hazards emitted from electric arc and contaminants such as oil and grease.
laser welding have the potential to cause eye
disorders and skin burns such as ‘arc eye’ or Never weld or heat empty containers, or weld in
‘welder’s flash’. confined or poorly ventilated areas.
Radiation from laser welding is less obvious than Provide personal protective equipment (PPE), such as
from electric welding arcs, but both are serious filter shades for goggles, face shields to protect
hazards. Workers directly involved in welding processes the eyes from radiation, gloves and other protective
are at the greatest risk, however other workers could clothing to cover exposed skin, that is:
also be exposed to harmful radiation. • suitable for the nature of the work and the
hazard (e.g. earmuffs, ear plugs)
Safety solutions and fit
Only allow competent (trained and experienced)
workers to be involved in welding. Trainees and • used or worn by workers who have been
apprentices should only be permitted to weld trained in its use and care.
if they are being trained and supervised by a
competent person. Further information
Code of Practice: Welding
Processes
30
Quick safety scans – machinery and equipment
Angle grinders Always Sometimes Never
Workers conduct pre-operational checks
Handgrips have an automatic cut-off or dead-man switch
Grinders have adjustable handles to suit both left and right-handed operators
Guards are kept in place (covering half the disc and positioned between the disc and the
operator)
Correct types of disc are used for tasks performed
Operators are trained/instructed in safe work procedures
Grinders are not used close to flammable materials
Plugs are removed from power points before changing discs
Regular short breaks are taken to prevent muscle fatigue when grinding for
extended periods
Grinders are regularly checked for electrical safety
Other workers are protected by a welding screen or stand well back when someone is
grinding
Safe work procedures are in place
Appropriate PPE is provided and used
Compressors and compressed gases Always Sometimes Never
Safety Data Sheets (SDS) are available for relevant gases
Cylinders are stored upright and restrained
Regulators and valves are maintained
Safe work procedures are in place
Air receiver/air tank is registered (if required)
Workers are trained in equipment use
Workers conduct pre-operational checks
A chemical register is available and is maintained
31
Electrical Always Sometimes Never
Outlets, plugs, sockets, leads and power points are in good condition
Temporary extension leads, multiple double adaptors and powerboards in series are not
used
Power circuits are protected with appropriately rated fuses or circuit breakers
Powerboards used for portable electrical equipment are RCD protected
Electrical equipment is never used in ‘wet’ areas
Unsafe equipment is disconnected/isolated/labelled
Testing and tagging is current for all fixed and portable electrical equipment
Main and isolation switches are clearly labelled/accessible
Electrical leads, power boards and equipment are kept away from potential sources of damage
(e.g. water, heat, being run over)
Compressed air or extra-low voltage equipment is substituted for electrically operated
Electrical equipment is maintained in good condition
Maintenance records are kept and available
Guarding Always Sometimes Never
Guards are designed and fitted to equipment, where required, according to relevant
Australian Standards and the manufacturer’s specifications
Guards are altered or removed with a tool (if permanent fixed or interlocked physical
barriers cannot be used)
Guards remain in place and plant is disabled if they are removed (deliberately or
unintended)
Guarding is maintained
Guarding enables easy servicing, maintenance or repair
Machines are turned off and disconnected when servicing, maintenance and repairs are
carried out
Pulley wheels on air compressors are guarded
Bench grinders/brushers/buffers are guarded (spark shields, side/upper tongue guards,

emergency stops, tool rests)
Pedestal drills are guarded (veebelt access restricted, emergency stops, rotating parts guarded)
Lathes and milling machines are guarded (rotating parts guarded, DC braking system, lead
feed screws, emergency stops), where practicable
Workers are fully instructed about safe procedures for guarding, isolation devices, locks, danger
tags and emergency stops
32
Noise Always Sometimes Never
Noisy tasks are identified, eliminated or minimised
Noise levels are kept below the exposure standard of 85dB(A) in an 8-hour day and below
the peak level of 140d(C)
Noise control guarding, screens or partitions are used
Advisory/warning signage is in place (e.g. Hearing Protection Must Be Worn)
Correct hearing protection (PPE) is provided and used
Critical situations can be communicated despite noise
Audiometric testing is carried out, if needed
Audiometric testing records are kept
Vehicle hoists Always Sometimes Never
Pre-operational checks are made daily
Inspections and maintenance are carried out, at least every 3 months
A comprehensive annual inspection is conducted
Inspection, servicing and maintenance records are kept in a log book
Workers are trained in correct and safe use of hoists
There is a minimum 600mm clearance between hoists and other equipment or

fixed structures
Safe working load is displayed
Operating and maintenance instructions are displayed
Vehicle jacks Always Sometimes Never
Inspections and maintenance are carried out, at least every 3 months
Inspection, servicing and maintenance records are kept
Workers are trained in correct and safe use
Operating and maintenance instructions are displayed
33
Vehicle ramps and stands Always Sometimes Never
Routine inspections and maintenance are carried out
Inspection, servicing and maintenance records are kept
Axle stands are based on solid and secure footings
Vehicles on ramps are secured to prevent movement
Operating instructions are displayed
Welding Always Sometimes Never
Welding equipment is used according to the manufacturer’s recommendations
Non-flammable welding screens/partitions are used
Signs warn that welding is taking place, and entry to the work area is restricted
There is adequate ventilation
PPE is provided and used (e.g. masks, aprons, gauntlets)
Workers are trained in the use and care of PPE
Oxy/gas cylinders are secured in trolleys or prevented from falling (e.g. chained)
Flashback arrestors are fitted at the blow pipe and to the oxygen and fuel gas regulators
34
Slips,
trips and
falls
Slips, trips and falls
Slips, trips and falls are the second most common Fall hazards are found where work is carried out
cause of workplace injury, after hazardous manual both at height (e.g. storage rack stacking) and at
tasks. Some common hazards arise from: ground level where there is a risk of falling into a
• type and stability of floor or ground surfaces (e.g. hole (e.g. service pits).
uneven or broken concrete, sloping ground)
• slippery floor surfaces (e.g. from water, spilled Further information
fluid, oil) Code of Practice: Managing the Risk of Falls
• equipment, boxes and materials blocking at Workplaces
walkways safework.sa.gov.au/cop
• stairs or steps
• carrying things that obscure the view
ahead
• poor lighting
• inadequate or improper footwear
• incorrect use of ladders
• falling or moving objects.
35
Floors, walkways, stairs
and landings
Hazards/risks
Uneven, poorly maintained or slippery floor
surfaces, obstructed/restricted walkways and poor
housekeeping can lead to slips, trips and falls.
Safety solutions
Report and repair any damaged floors and surfaces.
Clearly mark all walkways, ensure they are of

adequate width, and implement a clean and clear
walkway policy.
Design electrical and air plug-in points to limit cords

and hoses across workshops.
Attach mats to floor surfaces.
Restrict access to areas that are potentially

hazardous.
Provide ramps, not steps, where floor level

height changes.
Provide adequate lighting.
Use warning signs (e.g. wet floors).
Implement a ‘good housekeeping’ policy

(e.g. for rubbish, waste products etc). to keep all
work areas clean and clear.
Further information
Australian Standard AS1657: Fixed platforms,
walkways, stairways – Design, construction
and installation
36
Instruct workers in these
Ladders rules of ladder use:
• When setting up or moving a ladder
check for overhead obstructions (e.g.
Hazards/risks electrical cables).
• Place ladders on firm, dry, level ground,
If ladders are unsafe or used incorrectly, this can result
engaging all locks and braces.
in serious injuries caused by falls from height, ladders
slipping and falling objects. • Ensure compliance with the
manufacturer’s load rating.
Ladders should only be used if there is no other
reasonably practicable means of accessing • Only one person should be on a ladder at any
different levels that is safer and more efficient. given time.
• When ascending or descending, maintain 3
Extension or single ladders should only be used as a
means of access to or egress from a work area. They
points of contact at all times – 2 feet and 1
are not a place to work from except for light work of
hand, or 2 hands and 1 foot.
short duration that can be carried out safely. • Cimb and descend facing the ladder.
When working space and movement area are • Never carry anything when climbing or
restricted on ladders, awkward and limited working descending.
positions can lead to musculoskeletal disorders. • Keep centred between the ladder sides.
• Never lean sideways or over-reach.
Safety solutions • Be careful when pulling or moving items
from above (e.g. from shelves) as this may
Select a ladder that is the most suitable for the job and cause over-balancing or objects falling on
the work environment (e.g. aluminium ladders can people below.
easily be damaged if exposed to acids, and only non-
• Never stand above the ladder tread or
conductive, insulated ladders should be used for
electrical work or near electrical hazards). rung indicated as the maximum safe
working height.
Use ladders rated for industrial use (at least 120kg) • Only conduct light work from a ladder.
as they are designed to carry more load and are of
stronger construction than domestic types. • If a ladder is placed near a doorway, fix the
door in the open position or close and lock
Ensure ladders are fitted with non-slip safety feet. it. Alternatively, place another person on
Store ladders in a dry place to prevent warping or guard at the foot of the ladder. Warning signs
corrosion and check their condition frequently. may also be used.
Have ladders periodically serviced by a competent • Only use step or trestle ladders in the fully
person (someone who is qualified either through open position. A rigid metal spreader or
experience and/or training). locking device must be used and the load
carried by the front stiles.
Further information
• AS/NZS 1892.1 Portable Ladders: Metal
• AS/NZS 1892.2 Portable Ladders: Timber
• AS/NZS 1892.3 Portable Ladders:
Reinforced plastic
• AS/NZS 1892.5 Portable Ladders: Selection,
safe use and care
37
Service pits Cover pits when not in use with either traditional
hardwood covers, or the better solution of heavy
interlocked steel plates designed to run through
guide rails (much like a roller shutter).
Hazards/risks
Use ventilation systems with vents in the side walls
The hazards of working in or around vehicle service of the pit to vent vapours and fumes.
pits can include falls into an unguarded or uncovered
pit, asphyxiation, explosion or fire. Ensure all portable or permanent lighting and/or
electrical equipment within the hazardous zone of the
Some fuel vapours from vehicles and gaseous by- pit is intrinsically safe.
products of combustion have a tendency to settle
in low areas, such as vehicle service pits. Never drain a petrol tank or service LPG-powered
vehicles over or next to a service pit.
Service pits have poor ventilation which can allow
hazardous atmospheres to develop. Avoid work involving welding or oxy cutting
inside or adjacent to service pits.
Risk control measures should be based on fall
prevention, ventilation and fire safety.
Read more about working in confined spaces on

page 52.
Read more about fire and explosion on page 54.
Safety solutions
Provide multi-purpose hoists and elevated ramps for
overhead work, rather than the conventional service
pit.
Paint the pit interior white and outline the edges for
at least 600mm in a conspicuous colour
(e.g. safety yellow).
Install sectionalised guard railing designed to fit into

prepared floor sockets, or suspend chain barriers
from removable steel uprights to prevent people
walking into open pits.
38
Storage and racking Safety solutions
Ensure racking is suitable for the product type and
that load ratings are known and not exceeded.
Hazards/risks
Ensure tyres and parts are not stored above
Risks arise from the use of high force and/or shoulder height, or at too low a level.
awkward postures from the manual lifting,
Keep minimum stock on-site, based on usage rates, to
lowering and handling of materials, stock and
avoid over-stacking or crowding of storage areas.
equipment.
Minimise double handling by creating storage areas
Stacking that is unstable, unbalanced or too high
as close as possible to where work is done.
creates an issue, as do falls from height (e.g. from
ladders and mezzanine storage areas). Exceeding safe Strictly follow limits on layered/pyramid stacking.
working load ratings and damaged supports are also
risks. Roll, rather than lift by hand, car and truck tyres
and wheels, or use mechanical aids.
When using mechanical lifting and positioning aids
(e.g. forklifts) to lift, stack or transfer stock, other Use mobile access platforms to access stock stored
hazards related to traffic management and above shoulder height.
equipment use are introduced. Ensure mezzanine storage areas have guard rails
This includes the use of attachments not authorised and purpose-built stair access with a hand rail.
for use on forklifts. Read more about forklift safety Use appropriate, industrial use, A-frame platform
on page 44. ladders, following the rules on page 37.
Use mechanical aids to lift items up to racking

above shoulder height or to mezzanine storage.
Store tyres and parts in ‘stillages’ (e.g. crates, bins,

pallets, racks) that can be safely stacked and/or moved
with a forklift. Implement a strict traffic
management plan if forklifts are used.
Do not allow workers to stand on forklift arms as

part of loading and unloading.
A Licence to Perform High Risk Work is required

for forklift operation. While forklifts offer a practical
materials handling solution, they continue to be
associated with workplace deaths and injuries.
Further information
SafeWork SA High Risk Work – Guide to
Forklift Safety
safework.sa.gov.au
39
Quick safety scans – slips, trips and falls
Floors, walkways, stairs and landings Always Sometimes Never
All areas are free of slip and trip hazards (e.g. air lines, hoses, electrical cables and leads, tools,
spills, boxes, rubbish, uneven surfaces)
Fluid spills are cleaned up immediately
Walkways, ramps and steps are wide enough, clearly marked and free of obstructions
External areas (e.g. carparks, pathways) are free of slip and trip hazards (e.g. potholes, uneven
paving)
Drains are covered
Sumps (waste oil) are emptied regularly, and there is no overflow
Floor surfaces and mats are in good condition to prevent slipping when wet or
contaminated
Stairs and hand rails (where required) are in good condition (e.g. anti-slip treads)
Stairway landings are clear
Advisory/warning signage is in place (e.g. Slippery When Wet/Beware of Opening Door)
All areas are well lit
Workers are provided with/instructed to wear non-slip footwear
Ladders Always Sometimes Never
Ladders used are stable and in good condition, and only used for their designed
purpose
Non-conductive, insulated ladders are used for electrical work or near electrical hazards
Ladders are rated for industrial use (at least 120 kg)
Manufacturer’s load rating is complied with
Ladders meet Australian Standards
Workers are instructed in rules for ladder use
All ladders are regularly checked and periodically serviced
Step/trestle ladders are only used in fully open position
Non-slip rubber feet are fitted
Work platforms are used for access to work at height
40
Service pits Always Sometimes Never
Multi-purpose hoists/elevated ramps are used (so work is done overhead, not in a service
pit)
Pit interiors are painted white and the edges outlined in a conspicuous colour
Pits guarded/chained as fall protection
Pits are covered when not in use
Adequate ventilation is provided
Lighting is safe
Explosion/fire risks are assessed
Work involving welding and oxy cutting is avoided inside or adjacent to pits
Storage and racking Always Sometimes Never
Materials are stored to minimise lifting and enable good manual handling practices
Parts are stored in appropriate areas with racking, shelves etc
Limits are followed on layered/pyramid stacking
Tools and equipment are stored appropriately, and returned to storage when not in use
Shelving is in good condition, stable and securely fixed
Shelving is not overloaded or overstacked (as per certified load ratings)
Industrial use, A-frame platform ladders are used
Mobile access platforms are used to access stock above shoulder height
All materials are stored to prevent falling, and are free from projections and sharp edges
Overhead/mezzanine storage has guard rails/kickboards and purpose-built stair access with
hand rail
Overhead/mezzanine storage is designed for load-bearing purposes
Mechanical aids are used to lift stock to mezzanine levels or above-shoulder-height storage
Tyres and wheels are rolled, or mechanical aids are used
Tyres/parts are stored in stillages
41
Traffic
managemen
t
Traffic management
Where there are cars, trucks or forklifts at your The plan should take into account the size of your
workplace there is a risk that they will collide with workplace, the kinds of vehicles likely to be present,
people. Those who work with or near vehicles are and how often the interaction between people and
most at risk, as are customers and visitors. vehicles is likely to occur.
Workers unfamiliar with the operation of a Different controls are required if personnel are
particular vehicle or a customer’s driving ability working at another location or workplace with
can add to the risk from moving vehicles. which they are not familiar (e.g. making a service
call or carrying out roadside breakdown
Traffic areas in workplaces must therefore be maintenance).
controlled.
A traffic management plan is a set of rules for Further information

managing the safest and most efficient movement of
traffic at your workplace. It should contain practical, Safe Work Australia’s General guide for workplace
workable controls for all vehicles, including forklifts. traffic management
safeworkaustralia.gov.au
43
Forklift All forklift operators must have a current Licence
to Perform High Risk Work.
s
Remove keys when forklifts are not in use.
Hazards/risks Ensure the weight carrying capacity is clearly
Forklifts offer a practical materials handling solution, marked and followed.
however they continue to be associated with Conduct pre-start checks.
workplace deaths and injuries. While they are
compact and manoeuvrable, they can become unstable Regularly service and maintain forklifts,
when carrying loads. and keep these records.
Even at low speeds, forklifts can cause serious Ensure correctly fitted seat belts are worn by
injuries. It’s not just the operator who may be injured: operators.
pedestrians/other workers/visitors can also be struck by
Fit fall prevention cages.
a forklift or its load.
Forklift tines are not used for any unintended
The best way to reduce the risk of forklift-related
purpose (e.g. workers do not stand or travel on
injuries is to separate pedestrians and forklifts. This
them).
should be the most important aim of your traffic
management plan. Forklift tines are lowered when not in use.
Everyone affected by the plan must understand and Use only approved forklift attachments.
follow it.
Further information
Safety solutions SafeWork SA’s High Risk Work – Guide to
Develop a traffic management plan in consultation Forklift Safety
with forklift operators and other workers. safework.sa.gov.au
Clearly mark forklift ‘roadways’ that are separated
from pedestrian walkways (e.g. use exclusion zones
and impact barriers).
Set speed limits (close to walking pace) and ensure

they are followed.
Ensure operators travel in a manner that does not

result in reduced visibility due to the load placement.
Designate a safety zone for the delivery driver –

they should be seen by the forklift operator at all
times when their vehicle is being loaded or
unloaded.
Introduce clear and effective communication

systems between the forklift operator and the
driver (e.g. hand signals or two-way radios).
If in the same working zone, operators and

pedestrians should wear high-visibility vests.
Use flashing lights, reverse beepers and warning

sounds/horns.
44
Movement of vehicles Safety solutions
Designate pedestrian exclusion zones and
walkways.
Hazards/risks
Fix mirrors at blind corners and other areas to
Moving vehicles are a significant hazard to workers aid visibility.
and pedestrians, and are difficult to avoid in
Use a person to direct reversing vehicles – this
automotive workshops.
person should be in visual contact with the driver at
Workers may not be competent in the operation of all times and wear high-visibility clothing.
or familiar with the controls of all the different
Keep non-essential workers away from
vehicles they are asked to drive or move around the
reversing areas.
workplace.
Ensure reversing areas are well lit and clearly
Driving onto or off hoists can also present risks.
marked with signs or line markings.
Ensure workers have appropriate drivers’ licences

(full or provisional).
Train workers in different vehicle controls and

operation, and in driving on/off hoists.
Clearly mark exclusion zones with physical barriers

(e.g. chains or bollards), signs, reflective paint or
witches’ hats.
Designate a safety zone for the delivery driver –

they should be seen by the forklift operator at all
times when their vehicle is being loaded or
unloaded.
Introduce clear and effective communication

systems between the forklift operator and the
driver (e.g. hand signals or two-way radios).
Provide ways to warn pedestrians and vehicle

drivers that loading/unloading is in progress (e.g.
signage, cones, lights, alarms and horns).
45
Roadside maintenance The following factors need to be considered:
• safety of the work area (e.g. lighting, visibility,
hazards, ground stability)
Hazards/risks • signs and lights from/on/around/adjacent to the

disabled vehicle and assistance vehicle to warn
Hazards when working on a roadside include high- approaching drivers (e.g. high-visibility triangles/
speed traffic, poor visibility, weather and ground cones, flashing lights)
conditions. Workers could be struck by a passing
• provision of high-visibility, retro-reflective
vehicle or crushed by the vehicle moving off the jacks.
clothing to capture vehicle headlights at
Other risks related to isolation and communication dusk/night
arise if workers are required to work off-site or • vehicle payload stability
provide roadside assistance.
• availability of lifting or manual handling aids
(e.g. wheel dolly, brake drum lifter)
• two-way communication with workshop
Safety solutions
supervisor or another person
Ensure workers are comprehensively trained (and • is police traffic control required to make
regularly retrained) in traffic control procedures and
the area safe?
dynamic risk assessments when undertaking roadside
maintenance. • towing the vehicle to a safe work area before
repairs are attempted.
46
Quick safety scans – traffic management
Forklifts Always Sometimes Never
A traffic management plan is followed
Forklift ‘roadways’ are clearly defined and separated from pedestrian walkways
Exclusion zones are clearly marked with signs and/or barriers
There is a designated safety zone for delivery drivers when vehicles are being loaded or
unloaded
Clear and effective communication systems are in place between forklift operators and
drivers
There is a system for warning pedestrians and drivers that loading/unloading is in

progress (e.g. signage, cones, lights, alarms, horns)
Speed limit (close to walking pace) is followed by operators
Pre-start checks are completed
Weight carrying capacity is clearly marked and followed
Reverse beeper, flashing light and warning sound are working
Keys are removed when forklifts are not in use
Fall protection cages are fitted
Only approved forklift attachments are used
Forklift tines are not used for any unintended purpose
Forklift tines are lowered when not in use
Forklifts are regularly serviced
Maintenance and service records are kept
Operators wear correctly fitted seat belts
Operators and pedestrians wear high-visibility vests
Operators have a current Licence to Perform High Risk Work
47
Movement of vehicles Always Sometimes Never
Designated pedestrian exclusion zones and walkways are identified and in operation
Mirrors are fitted to blind corners
Another person (wearing high-visibility clothing and in visual contact with the driver)
assists with directing reversing vehicles
Situations where reversing is required are minimised (e.g. drive through instead)
Non-essential workers and pedestrians are kept away from reversing areas
Reversing areas are well lit and clearly marked
Roadside maintenance Always Sometimes Never
Workers are trained (and regularly retrained) in traffic control procedures and dynamic risk
assessments
You have an effective means of two-way communication between the workshop

supervisor and isolated/remote workers (e.g. mobile/satellite phone, UHF radio)
Signs/lights (e.g. high-visibility triangles/cones, flashing lights) are provided to warn

approaching drivers of disabled vehicles/assistance vehicles
High-visibility, retro-reflective clothing is provided
Lifting or manual handling aids are available (e.g. wheel dolly, brake drum lifter)
48
Hazardous
substance
s
Hazardous substances
Hazardous substances include paints, solvents, lead, • burner flames
powders, lacquers, paint removers, resins, battery • frictional sparks
acid, used oils, adhesives, degreasers, surface
preparation products, rust converters and removers, • broken electric light globes that expose the
and dusts. hot filament
• hot surfaces (e.g. operating internal combustion
Hazardous chemicals are substances and mixtures that
can be a health hazard if not handled or stored engines, heated wires, glowing metals, overheated
correctly. bearings)
• products that can be self-heating or result in
Dusts primarily arise from cutting, grinding and
spontaneous combustion
sanding. They have a direct route of exposure to the
lung and intestinal tract, and can be an irritant to eyes • catalytic reactions
and the skin. Asbestos dust may also be an issue – read • chemical reactions (e.g. mixing or decanting
more on page 50. hazardous chemicals can generate heat or static
electricity).
Vehicle emissions, particularly diesel, are a serious
problem in automotive workshops, as are welding and Exposure standards
paint fumes.
You must ensure that workers are not exposed to
Health effects airborne contaminants above workplace exposure
standards.
Short-term (acute) health effects from hazardous
substances and chemicals may include contact The list of exposure standards is contained within the
dermatitis, burns to the skin and eyes, vomiting and publication Workplace Exposure Standards for
diarrhoea, irritation to the nose/lungs/throat, Airborne Contaminants (also available within
headache and occupational asthma. the Hazardous Substances Information System
database). The publication, database and current GHS
Long-term (chronic) effects include lung cancer,
classification chemicals list can be accessed from
chronic dermatitis, chronic obstructive airway
safeworkaustralia.gov.au.
disease, and damage to the reproductive system,
kidneys and liver.
Health monitoring
Fire and explosion
Health monitoring by a registered medical practitioner
The use and storage of flammable and oxidising experienced in health monitoring must be conducted
substances (e.g. gases, solvents, combustible dusts used where there is a significant risk of workers
during powder coating, paints) can create serious fire developing an occupational disease due to exposure to
or explosion hazards when they come into contact hazardous substances
with potential ignition sources such as: (e.g. Isocyanates) or asbestos.
• welding or cutting torches
Further information on health monitoring, including
• matches, cigarettes and lighters links to Safe Work Australia’s guidance material for
• sparks and arcs generated by the discharge of static PCBUs, medical practitioners and workers, can be
electricity from poorly earthed equipment and found on the SafeWork SA website.
portable electric tools, power points, radios and safework.sa.gov.au
mobile phones
49
Asbestos Safety solutions
Develop and implement a comprehensive asbestos
removal management plan for brake, clutch and gasket
Hazards/risks work. If in doubt, seek advice.
Exposure to dust containing asbestos fibres may Train workers in safe asbestos removal methods.
exist while repairs are undertaken to brakes, clutches
Supervise work to ensure that management plan
and high-temperature gaskets in
procedures are followed, and regularly review the
older vehicles.
effectiveness of the plan with workers.
Prohibitions on the supply, sale, storage, use, re-
Keep an asbestos register.
use, installation and transport of asbestos-
containing products came into effect across Provide disposable personal protective equipment
Australia on 31 December 2003. Replacement (PPE) that is:
brake pads, brake shoes and clutch plates that are • suitable for the nature of the work and the
to be fitted to vehicles in Australia must be hazard (e.g. gloves, masks, goggles, face
asbestos-free. shields, respirators)
Despite the prohibitions, the potential for exposure • comfortable to wear, and of a suitable size
to airborne asbestos fibres in motor vehicle and fit
workshops may still remain until asbestos
components have been progressively removed from
older vehicles. • used or worn by workers who have been
Further information
For more information on identifying asbestos-
containing components and controlling health
risks from asbestos exposure, refer to the Code
of Practice: How to Manage and Control
Asbestos in the Workplace.
Asbestos may also be present in products

such as cement wall cladding, tiles,
lino or older roof cladding that are
part of your workshop building
structure, especially if it was built
before 1990.
Find out more at asbestos.sa.gov.au.
50
Batteries Inform, instruct and train workers in safe
procedures for using, handling, charging,
storing or maintaining batteries.
Hazards/risks Regularly check batteries for signs of physical

damage or deterioration.
Lead acid batteries are capable of delivering an
electric charge at a very high rate.
Ensure spill containment and first aid facilities are
Gases released when batteries are charging – available in case of an incident.
hydrogen (very flammable and easily ignited) and
oxygen (supports combustion) – can result in an Provide PPE that is:
explosion. • suitable for the nature of the work and the
hazard (e.g. when handling or using batteries or
The acid used as an electrolyte in batteries is also
the electrolyte)
very corrosive and can cause injuries if it comes into
contact with workers. • comfortable to wear, and of a suitable size and
fit
Electrolyte that has been spilled can also cause
significant damage to property and the • maintained, repaired or replaced when required
environment. • used or worn by workers who have been
Further information
Safety solutions
SafeWork SA Safety Alert – Lead acid
Check the manufacturer’s instructions, including batteries
Safety Data Sheets, for electrolyte spill
safework.sa.gov.au
containment, clean-up and disposal details, and
appropriate personal protective equipment (PPE).
51
Confined spaces Safety solutions
Eliminate the risk as the preferred option
(e.g. carry out the work from outside the space).
Hazards/risks
Substitute the risk, isolate the risk or apply
Larger vehicles may contain internal areas where a engineering controls (e.g. consider the nature of a
hazardous atmosphere may occur by design, or as a confined space and the internal atmosphere).
result of the work being done.
A risk assessment must be done. A confined space entry
Spraying inside the cavity of vehicles can cause permit completed by a competent person may be used
exposure to hazardous chemicals, unsafe oxygen as a record of the risk assessment.
levels and the potential for fire or explosion.
Implement safe work practices.
If environmental conditions in service pits are
Ensure workers are trained and competent to work in
conducive (e.g. limited natural airflow),
confined spaces.
concentrations of vapours and/or gases may build
up to dangerous levels. Asphyxiation may result, or Ensure an emergency response procedure is developed
an explosion or fire may occur if flammable vapours specifically for emergencies involving confined spaces,
or gases contact an ignition source. including a safe recovery process.
Ensure a competent stand-by person is placed outside

a confined space for support and in case of
emergency.
Provide ventilation in service pits.

is:
hazard (e.g. masks, goggles, face shields,
respirators)
and fit
• used or worn by workers, who have been
Further information
Code of Practice: Confined Spaces
A sample Confined Space Entry Permit can be found

on page 93. This is a sample document for you to
personalise and tailor to suit your particular business
needs and operations.
52
Dusts, fumes and gases Safety solutions
Regularly inspect and clean ventilation and dust
collection systems to remove dust build-up.
Hazards/risks
Isolate the hazard by either enclosing processes or
Workers may be exposed to a variety of airborne using remote operation (e.g. pendant controls,
substances such as dusts, fumes, gases, vapour, mists enclosed vehicle cabs, control rooms).
and smoke. The aim is to keep
Install local exhaust ventilation to capture dust,
concentrations of all airborne contaminants as low
fumes and gases at the source (e.g. use on-tool
as is reasonably practicable, regardless of whether they
extraction when cutting or sanding).
are known to present a health hazard.
Vehicle emissions, particularly diesel, are a serious
is:
problem in automotive workshops, as are welding and
paint fumes. • suitable for the nature of the work and the
hazard (e.g. gloves, masks, goggles, face
Cleanup of dusts, in particular, can exacerbate the shields, respirators)
problem through re-suspension, and the risk can be
transported from the initial exposure/emission point
and fit
to another (e.g. by air, wind, on clothing).
Dusts, fumes and gases can also pose a potential fire
or explosion risk.
Adopt good
trained in workplace
its use and hygiene
care. practices – have a
Asbestos dust may also be an issue – read more on regular cleaning routine, preferably using vacuuming
page 50. or wet mopping instead of sweeping.
Dusts, fumes and gases can accumulate or remain Lunchrooms and/or non-work areas should be
suspended in the air long after their production has considered clean zones, and contaminated PPE must
ceased. be removed before entering these areas.
Further information
For further information on respiratory protection,
refer to Australian Standards:
• AS/NZS1715: Selection, use and
maintenance of respiratory protective
equipment
• AS/NZS1716: Respiratory protective devices
SafeWork SA Safety Alert – Local

exhaust ventilation
safework.sa.gov.au
Refer also to the fact sheet Controlling construction

dust with on-tool extraction available from
hse.gov.uk/pubns/cis69.htm.
53
Fire and
explosion
Hazards/risks
Fire and explosion can result in catastrophic
consequences causing serious injury or death, as
well as significant property damage.
They occur when three primary elements

come together:
• a fuel source (a flammable or
combustible substance)
• an oxygen source (usually in the air)
• an ignition source (sufficient to cause
ignition).
Safety solutions
Store flammable materials in their original, clearly
labelled and tightly sealed containers, away from heat
sources, ignition sources or direct sunlight.
Store flammable and oxidising gases outdoors, in a

mesh cage (if possible), and separate them from each
other by a distance of at least 5 metres.
Keep flammable, explosive or combustible

substances at the lowest practicable quantity.
Remove hazardous substances that are not immediately

needed (e.g. keep the quantity of spray material in
spray areas to a minimum so that it does not exceed
what’s required for one day’s operations).
Return unused or surplus liquids to their designated

containers to avoid mixing different liquids.
Eliminate short circuits.
Have suitable, regularly maintained fire

extinguishers readily available.
Ensure workers are trained in the use of

fire-fighting equipment.
Consider installing a fixed, automatic fire-fighting

system, which should be regularly serviced.
Dispose of all waste materials, including chemicals and

paint /solvent-soaked rags, as soon as possible.
54
Hazardous chemicals
Hazards/risks
Some chemicals act as skin irritants, carcinogens or
respiratory sensitisers, with adverse health effects
usually arising from exposure through inhalation,
direct skin contact or ingestion.
Many chemicals can cause a sudden and very

strong reaction when they come into contact with
bare skin.
Hazards can result from the chemical or physical

properties of some substances – they may be
flammable, corrosive, oxidising or explosive.
Substances that can cause contact dermatitis include

acids, alkalis, oils, solvents, petroleum products, soaps
and detergents. Manufactured products which may
affect the skin include synthetic rubber, plastics,
fibreglass, resins and glue.
From 2017 South Australia has adopted a new system

of chemical classification and hazard
communication – the Globally Harmonised
System of Classification and Labelling of
Chemicals (GHS).
This replaces all previous systems and is now used

to classify the physical health and environmental
hazards of workplace chemicals and to standardise
information on labels and Safety Data Sheets
(SDS). Visit safeworkaustralia.gov.au for more
information.
Read more about exposure standards and health

monitoring on page 49.
55
Safety solutions Provide cleansers made from vegetable oil to ensure
workers do not use solvents to remove grease and
Ensure the SDS for any chemical in use is readily other substances from their hands that will not wash
available. Manufacturers and importers of hazardous off with soap and water.
substances are required to provide warning labels and
SDS which list important information on handling Ensure workers promptly treat minor cuts and
products safely, including potential health effects, abrasions, regularly use moisturising creams, and
precautions for use, seek medical attention if they experience
safe storage suggestions and emergency first aid dermatitis symptoms.
instructions.
Further information
Maintain a central register of hazardous
Code of Practice: Managing Risks of
substances.
Hazardous Chemicals in the Workplace
Replace lids on containers after each use.
For specific information on what a manufacturer or
Ensure storage areas are fit for purpose importer must include in an SDS and label:
and well ventilated. • Code of Practice – Labelling of
Workplace Hazardous Chemicals
If possible, have tasks performed without using the
hazardous substance (e.g. by changing the method • Code of Practice – Preparation of Safety
or process). Data Sheets for Hazardous Chemicals.
Substitute hazardous chemicals or irritating safework.sa.gov.au/cop

substances with less harmful alternatives,
where possible. SafeWork SA Safety Alert – Contact
dermatitis
Use the smallest amount of chemical necessary.
safework.sa.gov.au
Train workers in the safe handling, use and
storage of chemicals (including information
about contact dermatitis).
Provide personal protective equipment (PPE)

that is:
• suitable for the chemical substances being used, the
nature of the work and the hazard
(e.g. gloves, goggles, respirators, barrier
creams), and as per the SDS
• comfortable to wear, and of a suitable
size and fit
• maintained, repaired or replaced when
required
• used or worn by workers, who have been Subscribe to the recalls section of the
Product Safety Australia website
productsafety.gov.au for daily
Ensure workers adopt good hygiene and recall notifications.
housekeeping practices (e.g. hand washing and
drying/cleaning up spills, splashes and sprays). These can then be delegated to one
Ensure trained first aid personnel and facilities or two responsible workers who
are available. are tasked with checking for and
removing recalled products from use.
56
Spray painting Safety solutions
and powder coating Use properly designed spray painting booths,
enclosed or partially enclosed.
Inspect and maintain spray booths regularly.

Hazards/risks Provide breathing air, if required.
The processes involved in spray painting and powder
Keep spray booths clear of residues and
coating are particularly hazardous due to a
overspray.
combination of factors such as the use, handling and
storage of hazardous substances, and exposure to Control spray drift in walkways, public areas and air
electrical, fire, explosion, noise and plant hazards. conditioning intake vents.
For some high risk activities, such as spray painting Provide personal protective equipment (PPE) that
and abrasive blasting, PPE should always be used to is:
supplement higher level control measures. • suitable for the nature of the work and the
hazard (e.g. gloves, masks, goggles, face
Read more about exposure standards and health
shields, respirators)
monitoring on page 49.
and fit
• usedrecords
Keep or worn of by
PPEworkers who have been
maintenance
trained
(e.g. filter in its use andofcare.
replacement respiratory protection).
Further information
Code of Practice: Spray Painting and
Powder Coating
• AS/NZS 4114.1: Spray painting booths,
designated spray painting areas and paint
mixing rooms – Design, construction and
testing
• AS/NZS 4114.2: Spray painting booths,
designated spray painting areas and paint
mixing rooms – Installation and
maintenance
• AS/NZS1715: Selection, use and
maintenance of respiratory protective
equipment
• AS/NZS1716: Respiratory protective devices
57
Quick safety scans – hazardous substances
Asbestos Always Sometimes Never
All asbestos-containing materials are handled safely and appropriately, as per Codes
of Practice
An asbestos removal management plan has been developed
The plan is regularly reviewed in consultation with workers
An asbestos register is kept
Workers are trained in safe asbestos removal practices
Health monitoring is carried out (if required)
Batteries Always Sometimes Never
Workers are trained in safe procedures for using, handling, storing and maintaining
batteries
There is a procedure for safe charging of batteries
Batteries are regularly checked for signs of physical damage or deterioration
Appropriate PPE is provided and worn when handling or using batteries or the
electrolyte
Spill containment and first aid facilities are available
SDS is available for electrolyte spill containment, clean-up and disposal
Confined spaces Always Sometimes Never
Risk assessments are conducted to determine if your workplace has, or work is carried
out in, confined spaces
Confined space risks are identified, eliminated or minimised
Confined space entry permits are completed by a competent person
Workers are trained and supervised when working in confined spaces
A specific emergency response procedure has been developed and drills conducted for
confined space emergency and recovery
A competent stand-by person is placed outside the confined space for support and in case
of emergency
Task-appropriate PPE is provided and used
58
Dusts, fumes and gases Always Sometimes Never
Ventilation and dust collection systems are regularly inspected and cleaned
Hazards are isolated by enclosing processes or using remote operation
Local exhaust ventilation is installed, where needed
Air quality is monitored (e.g. workers do not suffer from dry, irritated eyes)
Appropriate PPE is issued and worn
Risk assessments are conducted for processes generating dust, smoke, fumes or gases
Lunchrooms/non-work areas are clean zones
Good workplace hygiene is practiced
Fire and explosion Always Sometimes Never
Flammable liquid storage area is free of ignition sources
Spills are cleaned up quickly
The flammable liquids storage area has spill catchment (e.g. steel drip tray,
concrete bund)
Paint and solvent containers are earthed during decanting to stop build-up of static
electricity
Flammable liquids are only stored with compatible dangerous goods (e.g. no gas
cylinders)
Correct type of fire extinguishers are provided and signed appropriately
Fire extinguishers are regularly maintained
Fire extinguishers are located close to potential hazards (e.g. where flammable
substances are used)
Waste materials (e.g. paint/solvent-soaked rags) are disposed of as soon as possible
Rubbish is stored away from flammable substances
Flammable, explosive or combustible substances are kept at lowest practicable

quantities
Advisory/warning signage is in place (e.g. Caution – Risk of Fire/Risk of Explosion)
You have developed an emergency response plan, and it is tested on an annual basis
Emergency wardens are identified and trained to respond in case of an emergency
Emergency exits/evacuation routes are identified and signposted within the workplace
59
Hazardous chemicals Always Sometimes Never
Risk assessments are regularly conducted for hazardous chemicals
Safe work procedures are in place and workers are trained in the safe handling, use and
storage of hazardous chemicals
Legal requirements are met for storage, disposal and licensing
Workers are trained in the safe handling, use and storage of hazardous chemicals
SDS are available for all chemicals in use
A chemical register is kept
Dermatitis-causing substances are identified
Irritating substances are replaced with less hazardous alternatives
Chemical containers are clearly labelled
Containers are tightly closed when not in use
Chemical storage is appropriate and well-ventilated, in accordance with the SDS
Areas where chemicals are used are adequately ventilated
Good workplace hygiene and housekeeping is practiced
Waste oils and other products are disposed of appropriately
Emergency procedures are in place for management of spills and incidents
Spill kit/containment equipment is readily available and workers trained in its use
Advisory/warning signage is in place
Correct PPE (e.g. gloves, safety goggles, protective clothing, barrier creams) is provided and
used
Workers use vegetable oil-based cleansers, not solvents, for hand-cleaning
Workers care for their skin by promptly treating minor cuts and abrasions, and using
moisturising creams
Workers seek medical attention if they have dermatitis symptoms
60
Spray painting and powder coating Always Sometimes Never
Ignition sources are removed
Breathing air is supplied
Spray booth is clear of obstructions and the exit is clear
Spray booth is clear of residues and overspray
Mixing room has adequate ventilation
Spray booth is maintained and calibrated (service and filter change records are up-to-
date and kept)
Spray drift into other areas is controlled
Respiratory PPE is provided and used
Advisory/warning signage is in place (e.g. Respiratory Mask Protection Must Be Worn)
61
Wellbeing,
psychological and
physical health
Wellbeing, psychological
and physical health
The World Health Organization defines a healthy Well designed and managed workplaces can play a
workplace as one where workers and managers role in promoting worker health and wellbeing, as
collaborate to use a continuous improvement process well as minimising ill health and facilitating recovery
to protect and promote the health, safety and and return to work after injury or illness
wellbeing of all workers and the sustainability of the
workplace. A mentally healthy workplace protects and
promotes psychological health by preventing
While it is difficult to control what people do, eat, common psychosocial hazards such as fatigue,
drink or smoke in their own time, and how they are bullying, discrimination and stressful working
dealing with issues away from the workplace, it is now conditions.
widely accepted that these issues are directly related
to work health and safety. Workplaces are increasingly a setting for physical
health promotion and preventative activities (e.g.
The costs of sick leave and replacing those workers smoking, obesity, drug and alcohol use) to
who are forced to leave due to health psychological assess and improve people’s overall health as well
and physical problems can be a hidden productivity as reduce work-related injury.
issue with potential business impacts.
If workers are making unhealthy dietary and Further information

lifestyle choices, this can contribute to fatigue and Safe Work Australia’s fact sheet Preventing
impact on fitness for work. Those who aren’t Psychological Injury under Work Health
looking after their health and wellbeing are also less and Safety Laws
productive and more likely to be involved in safeworkaustralia.gov.au
workplace incidents.
There are also associated risks such as obesity and long- The ‘Healthy living’ section of the SA Health
term chronic disease (e.g. diabetes) impacting on the website provides tips and tools to foster better
wellbeing of workers. health, wellbeing and healthy lifestyles.
sahealth.sa.gov.au
And when you consider that workers could
potentially be exposed to workplace hazards such as
paints, chemicals, fumes and dusts, this can
heighten the potential risks of developing chronic
health issues.
63
Alcohol and drugs Some other solutions include:
• providing behaviour change/prevention
information and education, counselling and
rehabilitation arrangements
Hazards/risks
• creating opportunities for return to usual work
In Australia alcohol use is a daily part of many people's duties by affected workers
lives. Although the use of illicit drugs is not as
common, those who have used these drugs at least • providing food and low alcohol/non-alcoholic
once is reported to be increasing. alternatives if alcohol is allowed at functions
The effects of both alcohol and illicit drug use • providing alternative travel arrangements for
during and outside of work hours can have a workers affected by alcohol or drugs.
significant impact on workplace health, safety and
productivity. Co-ordination, motor control, Further information
alertness and ability to exercise judgement can Information about resources and services available to
become affected. This risk is greater where people help employers and workers is available at
operate machinery, drive or rely on concentration to safework.sa.gov.au.
do their work.
Framework for alcohol and drug
Prevailing workplace culture, availability, physical
management in the workplace, Workplace
isolation, job satisfaction and stress are a few
Health and Safety Queensland
of the other factors that might also increase the
worksafe.qld.gov.au
likelihood of alcohol or other drug consumption. Check with your industry association for any
Workers under the influence present an injury current alcohol and drug policies (e.g. Motor Trade
hazard to themselves. They may also place their Association SA mta-sa.asn.au).
workmates in danger or in the difficult position of
SA Health
being expected to cover for unsafe work practices
or having to report a fellow worker. Drug and alcohol emergency information.
sahealth.sa.gov.au
Damage to property or equipment and negative
publicity for a business are also potential issues.
Alcohol and Drug Information Service
A confidential telephone counselling, information
and referral service staffed by trained professionals.
Safety solutions Phone 1300 13 1340 from 8.30am to 10pm every
day (local call fee for South Australians) or visit
If an alcohol or other drug-related hazard is identified
sahealth.sa.gov.au.
in a workplace, you need to eliminate or reduce any
related harm, as far as is practicable.
Drug and Alcohol Services South Australia
Consider developing an alcohol and drug policy A range of information resources, pamphlets and
which sets out everyone's responsibility to ensure a posters for download, some available for order.
healthy and safe work environment. The content sahealth.sa.gov.au
should be based around an assessment of the
associated risks and the individual requirements beyondblue
of your workplace. The policy should clearly state
Drugs, alcohol and mental health fact sheet.
what is acceptable and the consequences of any
unacceptable behaviour. Develop the policy in resources.beyondblue.org.au
consultation with your workers, communicate it
clearly to all members of the workforce, display it Counselling Online
and ensure that workers have read, understood and Free and confidential 24/7 online drug and alcohol
signed it. counselling and referral line, phone 1800 888 236.
counsellingonline.org.au
64
Bullying Further information
Safe Work Australia’s national bullying guides
explain what is and isn’t workplace bullying, how it
Hazards/risks can occur and how risks can be managed.
Workplace bullying can have a significant negative
impact on individuals and the workplace. Like all The employer’s guide shows how to identify the
hazards at work it needs to be managed. risk of bullying occurring. For example, it’s a good
idea to monitor incident reports and patterns of
Everyone at work has a responsibility for
absenteeism, and develop anti-bullying policies and
work health and safety – both physical and
procedures. It also explains how to respond to
psychological – and to ensure that bullying does not
bullying and conduct an investigation into allegations
occur.
of bullying.
The worker’s guide outlines where to get advice

Safety solutions and what steps to take if bullying is occurring.
It also provides information on what to do if a
Develop an anti-bullying policy in consultation workplace bullying report has been made. In
with your workers. addition, it highlights the new provisions of the
Commonwealth’s Fair Work Act 2009 which
Ensure workers are aware of the bullying reporting
allows the Fair Work Commission to consider
process.
individual applications to stop bullying.
Adopt a process for dealing with bullying
complaints.
Provide educational information and

support.
65
Fatigue
Hazards/risks Safety solutions

Fatigue is a state of mental and/or physical Avoid working during periods of extreme heat or
exhaustion which reduces the ability to perform cold, or minimise exposure time through job
tasks safely and effectively – it is more than just rotation.
feeling a little drowsy.
Encourage workers to report concerns they may
Being awake for 17 hours impairs performance to have about work-related fatigue.
the same level as having a 0.05 blood alcohol
Design working hours and rosters to enable
content. Being awake for 20 hours has the same
enough recovery time between shifts.
effect as a 0.1 blood alcohol content. 1
Everyone’s ability to remain alert can be reduced by Ensure workers take adequate and regular breaks to
rest, eat and rehydrate.
fatigue, which can adversely affect safety at work.
Fatigue can be caused by either work or

non-work factors, or a combination of both, and
Further information
can accumulate with time. For more information, refer to Safe Work
Australia’s national fatigue guides which provide
information about workplace fatigue: why it’s a
1 WorkSafe Victoria, WorkCoverNSW, Fatigue Prevention in problem, the signs of fatigue and how to mitigate the
the Workplace, August 2008
risks.
The guides outline the factors that can contribute to

fatigue (e.g. shift work), how the risks can
be assessed and controlled, and what workers’
responsibilities are in managing fatigue.
66
Health and wellbeing Business impacts
It is worth considering if your business could cope
without you if you had a significant health issue.
Hazards/risks If you have a team of workers, you also need to
consider the costs of sick leave and replacing those
Because working in a workshop is seen as a who are forced to leave due to health issues.
physical job, it's often assumed that it is also a
Having a healthy workforce makes sense because:
healthy occupation, with plenty of exercise and
fresh air. • poor employee health and absenteeism costs
Australian businesses $7 billion annually (or an
However, the reality is that workshop workers face a estimated $2700 per worker, per year) 1
number of different impacts on their personal health
• unhealthy workers take up to 9 times more sick
and wellbeing which may affect their ability to
leave than their healthy colleagues 1
remain fit and well.
• healthy workers are nearly 3 times more
Obesity is on the rise due to inappropriate food productive than unhealthy workers 1
choices, smoking is common, and alcohol and drugs
• presenteeism (not functioning fully while at
are used widely, especially by young workers and often
work, due to poor health) is estimated to cost
at high levels.
Australian business $26 billion per year in lost
Unhealthy dietary and lifestyle choices can affect productivity (2005/06) 2
fitness for work and productivity, and potentially • obesity-related poor health is estimated to cost
lead to long-term chronic disease, the risk of which South Australian businesses $273 million per year
may be heightened by exposure to other workplace (2008). 3
hazards (e.g. smoking combined with exposure to
chemicals, fumes and dusts). 1The health of Australia's workforce, November 2005,
Medibank Private
Poor health and wellbeing can also be a hidden
2Workplace Wellness in Australia, 2010, Price Waterhouse
productivity issue for many Australian businesses. Coopers
3The growing cost of obesity in 2008, report for Diabetes

Australia by Access Economics Pty Ltd, 2008.
Cost of sick leave Cost of replacement staff

Implementing a successful workplace health program can decrease Implementing a successful workplace health program can
staff absenteeism/sick leave by an average of 30%. decrease staff turnover by an average of 10%.
cost of
cost of sick leave replacement staff
$7200 $135 000
based on 30 sick days per
based on 3 workers resigning
workplace per year @ $30/hr
each year @ 75% of $60 000
annual wage
implement a workplace health program
Estimated savings
$2,160 $13,500
=
$15,660
67
Further information
Workplaces can act as a setting
Safety solutions for physical health promotion and
preventative activities.
Offer healthy food choices at the workplace.
Support workers to participate in regular physical The ‘Healthy living’ section of the
activity, through promotion, education and access to SA Health website provides tips
physical activity and involvement opportunities. and tools to foster better health,
wellbeing and healthy lifestyles.
Support worker wellbeing through work practices, a
• Try Get Healthy, a free,
positive workplace and leadership
confidential information and
telephone-based coaching service
that helps adults make lifestyle
changes in relation to healthy
eating, being physically active
and achieving and maintaining a
healthy weight.
• Download the Healthy Workers
Healthy Futures toolkit, a
guide to developing a
successful workplace health
program.
• Utilise Step 2 of the Healthy
Workers Audit Tool to do an
audit of how well your
workplace currently supports
worker health and wellbeing.
• Access the SA Brief Health
Check which assesses current
lifestyle and provides tips and
referrals to support change.
• Search for SNAP resources
(Smoking, Nutrition,
Alcohol, Physical Inactivity).
sahealth.sa.gov.au
68
Smoking Safety solutions
The following control measures are key to
successfully achieving a smoke-free work
Hazards/risks environment:
The Tobacco Products Regulation Act 1997 Commitment: Demonstrate senior management
prohibits smoking in all enclosed workplaces commitment and support to the development of a
(e.g. offices, shops, factories, work vehicles). smoke-free workplace policy.
Workplace exposure to passive smoke can produce Consultation: Consult with workers during the
symptoms of ill health, particularly for people with development and implementation of the policy.
pre-existing medical conditions (e.g. respiratory or
Policy: Following consultation, develop and
cardiovascular). Workers must be protected from the
communicate a written non-smoking policy. The
harmful health effects of exposure to second- hand
policy should ban smoking from the workplace and
tobacco smoke.
include all indoor areas, vehicles and areas where
Workers who smoke should not be stigmatised. smoke could drift into workplaces.
Support: Establish designated outdoor areas where

smoking is permitted. These areas should have
adequate natural ventilation and be placed where
smoke cannot drift into smoke-free areas.
Communication: Make management, workers,

customers and visitors aware of the policy. Use
signage so that everyone knows where they cannot
smoke (e.g. toilets, stairwells, foyers, staff rooms).
Offer encouragement to quit smoking by:

• placing health and ‘Quit’ information in
strategic locations (e.g. staff rooms)
• not selling cigarettes at the workplace
• inviting ‘Quit’ program providers to talk
with workers
• offering incentives to participate in
‘Quit’ programs
• referring smokers to the Quitline for help.
Further information
Further information and details of support are
available at safework.sa.gov.au.
SA Health has a smoke-free workplace guide

to help you meet your legal requirements and
support the development of smoke-free policies
– download it from sahealth.sa.gov.au.
69
Work-related stress
Hazards/risks
Workplace injury claims for stress-related mental
disorders are estimated to cost Australian business
more than $200 million annually. 1
Work-related stress describes the physical, mental and

emotional reactions of workers who perceive that
their work demands exceed their abilities and/or their
resources (such as time, help/support) to do the
work. Stress occurs when people feel they are not
coping in situations where it is important to them
that they do.
A worker’s response to stressors at work may be

positive or negative depending on the type of
demands placed on them and the amount of
control they have of the situation, as well as
support they receive and their individual response.
In the vast majority of instances people adjust to

stressors and are able to continue to perform
their normal work duties. While stress itself is not a
disease, where it becomes excessive and long-
lasting, it can lead to ill health.
Employers have a primary duty of care to ensure, so

far as is reasonably practicable, that the health and
safety of their workers is not put at risk. This duty
extends to protecting workers from the risk of harm
from stressors at work.
1 NOHSC 2003, from Work-related mental disorders in

Australia, April 2006, Safe Work Australia
Safety solutions
Workplace Health and Safety Queensland has a
series of 12 fact sheets on managing work-related
stress. worksafe.qld.gov.au
WorkSafe Victoria has a Stress-Wise kit that

explains the risks of work-related stress and what you
need to do to identify, prevent and manage them.
worksafe.vic.gov.au
70
Work-related violence
Hazards/risks
Work-related violence is any incident in which a
person is abused, threatened or assaulted in
circumstances relating to their work.
This definition covers a broad range of actions and

behaviours that can create a risk to the health and
safety of workers.
Work-related violence can result in both physical and

psychological injuries to workers, and cause significant
economic and social costs to them, their family, the
business where they work and the wider community.
Safety solutions
SafeWork SA’s guide Preventing and Responding
to Work-Related Violence helps employers and
workers identify work-related violence hazards and
ways to eliminate or minimise them.
Two types of work-related violence are covered:

• external violence – usually associated with
robbery or other crimes where the perpetrator is
someone from outside the workplace
• service related violence – arises when providing
services to clients, customers, patients or prisoners.
This guide will assist in the development of work

systems for the prevention of violent incidents, and
responses to them should they occur.
safework.sa.gov.au
71
Quick safety scans – wellbeing, psychological
and physical health
Alcohol and drugs Always Sometimes Never
You have a drug and alcohol policy, developed in consultation with workers
The policy is displayed in the workplace
Workers have read, understood and signed the documentation
Educational information and support programs are provided
If alcohol is allowed at work functions, you provide food and low alcohol/non-alcoholic
alternatives
Alternative travel arrangements are provided for workers affected by alcohol/drugs
Bullying Always Sometimes Never
An anti-bullying policy has been developed in consultation with workers
Workers are aware of the bullying reporting process
You have a process for dealing with bullying complaints
Educational information and support is available
An employee assistance program is available to workers
Fatigue Always Sometimes Never
Fatigue risks have been assessed
Strategies/policies are in place to handle risks
Fatigued workers are given time off work
Rosters allow for adequate recovery time between shifts
Health and wellbeing Always Sometimes Never
Healthy food choices are offered in the workplace
Workers are supported to participate in regular physical activity through promotion,

education and access to physical activity and involvement opportunities
Worker wellbeing is supported and promoted through work practices, a positive

workplace culture and leadership
Educational and information support programs are provided
72
Smoking Always Sometimes Never
A smoke-free workplace policy has been developed in consultation with workers
The policy is displayed in the workplace
You have designated outdoor smoking areas
‘No smoking’ signage is in place
‘Quit’ information and support is available
Work-related stress Always Sometimes Never
Work-related stress risks have been assessed
Strategies/policies are in place to handle risks
Work-related violence Always Sometimes Never
Work-related violence risks have been assessed
Strategies/policies are in place to handle incidents
73
Proformas
Sampl This is a sample document for you to personalise
and tailor to suit your particular business needs and
operations.
Work Health Workers must:
e
and Safety Policy
This policy shows the commitment of the management and
workers in this workplace to health and safety and:
• take reasonable care for their own health and safety, and
ensure that their acts or omissions do not adversely affect
the health and safety of others in the workplace
• follow reasonable instructions given by the PCBU to
• aims to remove or reduce risks to the health and safety protect their health and safety
of all workers, contractors and visitors to this workplace • identify and report any workplace incidents or
and anyone else who may be affected by our operations hazards to their supervisor
• aims to ensure all work activities are done safely • not wilfully interfere with or misuse items or facilities
• recognises that health and safety is most effective provided.
when a collaborative approach is used to identify and
solve problems
• commits to continuously improving work health Visitors and contractors must:
and safety by addressing hazards and reviewing • not put themselves or any other person at the
outcomes. workplace at risk
• comply with our safety policy.
The Person Conducting a

Business or Undertaking (PCBU) Policy authorised by
must:
• ensure their responsibilities under the Work Health
Name
and Safety Act 2012 (SA) and Work Health and
Safety Regulations 2012 (SA) are met
• take reasonable steps to provide and maintain a safe
working environment, plant and substances in a safe Signature
condition, and facilities for the welfare of all workers
• provide ways for workers to be informed about and
involved in health and safety issues at work Date
• provide information, instruction, training and

supervision needed to make sure that all workers are safe
from injury and risks to their health and safety Review date
• conduct regular workplace inspections
• ensure this policy and all safe work procedures are kept
up-to-date.
75
Sample This is a sample document for you to personalise
operations.
Record of Safety Discussions

Business name
Date Completed by
Persons present
Comments and issues raised
Action complete
Corrective action Action by
Date Sign-off
77
operations.
Hazard List and Risk Assessment

Business name
Date Completed by
Risk severity/ Likelihood Risk level

Hazard consequence (very likely, likely, (extreme, high, medium,
(fatality, critical, major,
unlikely, very unlikely) low, very low)
minor, negligible)
79
operations.
e
Business name
Date
Risk Control Plan
Completed by
Action required to control

Hazard Completion date Responsible person
the hazard
Extreme
High
Medium
Low
81
operations.
e
Worker’s name
Position / job title

Induction Checklist
Employment start date Supervisor / manager
Introduction (explain to new workers about ...)
the industry, nature and structure of your business
roles of key people in your business
job, tasks and responsibilities
Job introduction
demonstrate to the worker how to do the job correctly and safely
provide required information and supervision
introduce other workers and the supervisor
introduce the first aid officer and show location of first aid supplies
explain and demonstrate emergency procedures
show the location of exits and emergency/fire equipment
show the work area, toilet, drinking water and eating facilities
show how to safely use, store and maintain tools, machinery, hazardous substances and personal protective equipment
(PPE)
show where to make phone calls and collect messages
Employment conditions
work times and meal breaks
rates of pay and how payment is made
superannuation and other deductions
leave entitlements
notification of sick leave or absences
83
operations.
e
Health and safety
health and safety policy, safe work procedures (provide a copy)
roles and responsibilities of people in the workplace (e.g. Health and Safety Representatives)
hazards in the workplace, how they are controlled, and how to report them
how to report health and safety issues (including forms)
how they will be kept informed about and consulted on health and safety issues
work injury insurance claims (e.g. show where forms are)
incident reporting
communication (e.g. when in remote location)
Other requirements
quality procedures
security issues
hygiene procedures and facilities
Conducted by Signature Date
Worker’s name Signature Date
84
operations.
Training Plan
e
Use this plan with your Risk Control Plan to identify the training needs at your workplace and help you meet your work
health and safety responsibilities.
Business name
What training is
Control action W h o is to be trained? Ho w? When?
required?
85
operations.
e
Training Record
Business name
Date
Name of participant Course/topic Conducted by Participant’s signature
completed
87
operations.
Incident/Hazard Report
Business name
Date of incident Time (am/pm) Date reported
Name of person reporting the incident/hazard
First aid Medical treatment Hazard report
Notifiable incident
Near miss Property damage reported to SafeWork SA
Name of person injured (if applicable)
Nature of injury
Part of body injured
Location of the incident
Description of incident or hazard
How did the incident occur (contributing factors)?
1.
2.
3.
4.
5.
6.
89
operations.
e
Corrective actions
What needs to happen By when Person responsible
Sign-off
Name of person reporting Signature Date
Supervisor’s name Signature Date
Manager’s name Signature Date
90
Sample
Hazardous Substance Register
This is a sample document for you to personalise
operations.
Business name
Date Completed by
What is the Maximum

Location SDS
Product name Chemical name UN Number product used quantities
stored available?
for? stored
91
operations.
Confined Space Entry Permit

General
Location of work
Description of work
Isolation
Space needs to be isolated from (location/method)
Water / gas / steam / chemicals
Mechanical / electrical drives
Auto fire extinguishing systems
Hydraulic / electric / gas / power
Sludge / deposits / wastes
Locks and/or tags have been affixed to isolation points
Yes No
Atmosphere
The atmosphere in the confined space has been tested. Result
of tests
Oxygen Flammable gases Other gases
% % LEL ppm (less than ppm)
% % LEL ppm (less than ppm)
Other airborne contaminants
93
operations.
e
The conditions for entry are as marked below
1. With supplied air breathing apparatus Yes No
2. Without respiratory protection Yes No
3. With escape unit Yes No
Hot work
Area clear of all combustibles including atmosphere Yes No
Type of appropriate fire prevention equipment available
Suitable access and exit Yes No
Hot work permitted Yes No
Personal protective equipment

The following safety equipment must be worn (types)
Respiratory protection
Harness/ lifelines
Eye protection
Hand protection
Footwear
Protective clothing
Hearing protectors
Safety helmet
Communication equipment
Other
94
operations.
e
Other precautions
Warning notices/barricades Yes No
All persons have been trained Yes No
Continual air monitoring is required Yes No
Notes
Emergency response
Procedures / equipment
Standby person
Name
Procedures / equipment
Authority to enter
The control measures and precautions appropriate for the safe entry and execution of the work in the confined space have
been implemented and persons required to work in the confined space have been advised of and understand the
requirements of this written authority.
Signed (person in direct control) Date Time
This written authority is valid until Date Time
95
operations.
Contractor Safety Management

Name
Position
Company name
ABN Licence / registration number (if applicable)
Address
Phone number Mobile
Email
Names of your workers who could attend on site
Services provided
Provide a summary of any relevant insurances you hold

(e.g. public liability, workers compensation, personal accident/disability, relevant other).
Type Insurer Policy number Expiry date

1.
2.
3.
4.
5.
I have read and understood the CONTRACTORS SAFETY REQUIREMENTS attached.
Signed Name Dated
97
operations.
Contractor safety management requirements
e
1
2
As a contractor to our site, we regard you as a professional in your trade/area of expertise. You have responsibility for your own
safety and the safety of your co-workers and others that your work activities may impact upon.
All contractors are responsible for ensuring they, and all persons working for or contracted by them, have completed a basic site
induction and have read and understood the safety requirements detailed below. This must be done before starting work.
3 If working on a construction site, all workers must hold a White Card.
4 All contractors must sign in upon arrival and contact the person in charge of the area they will be working in. Sign
out when you leave the site.
5 No work is to start until contractors, and everyone working for them or contracted by them, have been authorised to do so
by the person in charge of the area they are working in.
6 Before starting work, all contractors working at this site have a duty to consult with other workers who may be affected by the
planned work activities and where work health and safety matters arise during the course of the work.
7 All contractor equipment, materials, and personal protective equipment (PPE) must be in good condition, properly
maintained and suitable for the job at hand. They must comply with the relevant legislative requirements and/or Australian
Standards.
8 All work must be conducted in a safe, healthy and environmentally responsible manner, and comply with all
legal/regulatory requirements.
9 Control any hazards (as deemed appropriate).

10 No equipment is to be repaired or maintained unless properly isolated/switched off and/or stopped.
11 Any equipment or materials found to be unsafe should be reported immediately to the person in charge and be tagged “out of
service”.
12 On a construction site, all mains-powered electrical equipment must have a current test tag.
13 A current safety data sheet must be available for any hazardous/dangerous chemical used.
14 For any high risk work (such as work at heights over 2m, confined space work, working with hazardous substances) you must have
appropriate training and the correct equipment. An appropriate formal risk assessment, safe work method statement or job safety
analysis must be completed before starting work.
15 PPE (e.g. hearing, foot, eye protection, hard hats, high visibility vests) must be worn/used as appropriate to the area and work
being carried out.
16 All injuries, incidents and equipment damage/breakages/failures are to be reported immediately to the person in charge. If
appropriate, an incident/injury form is to be filled out and submitted to the person in charge of the area.
17 A serious incident may be notifiable to SafeWork SA. Call 1300 365 255 to notify and preserve the scene of the incident.
18 Beware of vehicle traffic operating on site. Where possible, you must follow the designated pedestrian walkways
(designated by yellow lines).
19 Demarcate/isolate visitors/clients from the work you are doing with appropriate warning signage and barriers.
20 Do not enter any areas which you are not authorised to enter.
21 Agree to follow the business privacy/confidentiality policy.
22 Maintain reasonable standards of housekeeping, cleanliness and hygiene.
23 Smoking, alcohol and illegal drugs are prohibited at the site.
24 No form of harassment/bullying will be tolerated.
25 Understand site emergency requirements (basic evacuation procedures, exit locations, evacuation assembly location).
26 Comply with any reasonable direction from the PCBU, Principal Contractor or Site Management. You could be asked to leave the
site if any of the above requirements are not followed to reasonable expectations. Please ask the person in charge of your work if
any doubt exists.
27 Remember, at (Insert PCBU name) we want you to be safe at work so you can go home at the end of each day.
98
For free information, advice
and support please contact us:
1300 365 255

This publication is licensed under a Creative Commons Attribution
help.safework@sa.gov.au Australia Licence v3.0. For terms see:
http://creativecommons.org/licences/by/3.0/au/deeden.
safework.sa.gov.au Disclaimer | While care has been taken to ensure the accuracy and currency
of the information in this publication, at the time of reading it may not be
sufficiently accurate, current or complete to suit your individual needs.
@safeworksa Reliance on the information in this publication is at your own risk.
SafeWork SA accepts no liability for any loss resulting from your reliance
safeworksa on it. To best meet your work health and safety obligations refer to current
Acts, Regulations and Codes of Practice.
0932 JUNE2017
© Government of South Australia
2017

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Automotive

Slips, trips and falls ......................................................

And in many workplaces new

Start out by reading the Simple steps to safety

The following tabbed sections cover some of the

• state a commitment to improving work health

Monitoring and reviewing

Having followed these steps and established the ways

It may not be possible to eliminate a hazard if

Eliminate the hazards

Other Codes of Practice that are specific to the

Australian Standards can be searched for and

Product safety recall

Getting started Always Sometimes Never

The WHS policy is displayed and easily accessible

The WHS policy is regularly updated

Talking with your team Always Sometimes Never

You have procedures for resolving issues

Managing hazards Always Sometimes Never

Hazards are identified and their risks considered

Control measures are implemented for all identified hazards

Hazard identification, risk assessment and control processes are in place

Informing, training and supervising Always Sometimes Never

You speak to workers about their training needs

A training plan is in place

Records are kept of each worker’s training

You supervise workers in their tasks

You have a new worker induction program/checklist

There is a procedure for visitor/contractor sign-in and access to the workplace

You have an induction process if visitors/contractors will access hazardous areas

Regular safety checks/inspections are carried out

Incident reports are reviewed

Incident report forms are used

All notifiable incidents are reported to SafeWork SA

Record keeping Always Sometimes Never

Worker training records are kept

You maintain a hazard register

You maintain a chemical register

You maintain an asbestos register

Plant registration details are kept and easily accessible

Records are kept of testing and inspection of items of plant

Monitoring and reviewing Always Sometimes Never

You regularly review your safety processes with your workers

First aid Always Sometimes Never

An adequate number of people are trained to administer first aid

Eye washing facilities are provided

First aid records are kept

First aid signs are posted

Fire and emergency procedures Always Sometimes Never

Fire extinguishers are regularly maintained

Workers are trained in fire-fighting equipment use

Fire-fighting equipment is in good condition

You have an emergency response plan and evacuation procedure in place

Emergency lighting is available, visible and periodically tested

Emergency exits are clearly signposted and unobstructed

Smoke detectors are fitted, tested and maintained

Emergency contact numbers are displayed