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Managing Risks of Plant

What is Plant?​

Plant includes machinery, equipment, appliances, containers, implements and tools, and any component or fitting.

Construction Plant Examples:

  • Mobile plant: Excavators, loaders, forklifts, trucks, cranes, elevated work platforms (EWP)
  • Fixed plant: Concrete pumps, compressors, generators, scaffolding
  • Power tools: Saws, grinders, drills, nail guns, welding equipment
  • Pressure equipment: Air compressors, pressure vessels
  • Lifting equipment: Cranes, hoists, lifting beams, slings

Common Plant Hazards​

Mechanical hazards:

  • Crush points, shear points, entanglement
  • Ejected parts or materials
  • Moving parts (blades, gears, belts, chains)

Non-mechanical hazards:

  • Electricity
  • Noise and vibration
  • Heat, fire, explosion
  • Hazardous substances (fumes, dust, hydraulic fluids)

Operational hazards:

  • Rollover or tip-over
  • Collision with workers, structures, other plant
  • Falls from height (working on/near plant)
  • Loads falling from height

Who Has Duties?​

PCBUs​

Must:

  • Manage plant risks through risk management process
  • Ensure plant safe for intended use
  • Maintain plant in safe condition
  • Provide information, training, supervision
  • Ensure operators licensed/competent
  • Register certain high-risk plant

Designers, Manufacturers, Suppliers, Installers​

Must:

  • Ensure plant designed, manufactured, supplied, installed without risks
  • Provide safety information
  • Test and commission before supply

High-Risk Work Licences​

WHS Regulation requires licences for:

  • Cranes: Bridge/gantry, derrick, portal boom, tower, vehicle loading
  • Hoists: Materials hoists, personnel/materials hoists
  • Forklifts: All classes
  • Elevating work platforms (EWP): Boom-type (boom length of 11 metres or more)
  • Rigging: Basic, intermediate, advanced
  • Dogging: Directing crane operations, slinging loads
  • Scaffolding: Basic, intermediate, advanced
  • Pressure equipment: Boilers, turbines (in some jurisdictions)

[!important] Licence Verification Always verify operator licences before allowing operation. Licences available at Industrial Relations NSW

Risk Management for Plant​

1. Identify Hazards​

Throughout Plant Lifecycle:

  • Design: Inherent hazards in design
  • Purchase: Suitability for intended use
  • Installation: Commissioning, structural support
  • Operation: Normal use hazards
  • Maintenance: Access, isolation, stored energy
  • Decommissioning: Safe dismantling and disposal

2. Assess Risks​

Consider:

  • Potential injuries (severity and likelihood)
  • Who is at risk (operators, other workers, public)
  • When risks arise (operation, maintenance, emergencies)
  • Existing control measures

3. Control Risks: Hierarchy of Control​

Level 1: Elimination

  • Eliminate need for plant
  • Example: Pre-cast panels eliminate on-site formwork systems

Level 2: Substitution/Engineering

Purchase Safe Plant:

  • Select plant with built-in safety features
  • Example: Excavator with ROPS (rollover protective structure), proximity detection systems

Guarding:

  • Fixed guards (permanent barriers over dangerous parts)
  • Interlocked guards (machine stops when guard opened)

Fixed guard on rotating shaft Figure: Fixed guard preventing access to rotating shaft

Perimeter fence with interlocking door Figure: Perimeter fence guard with fixed panels and interlocking access door

  • Adjustable guards (for different operations)

Example: Circular saw with retractable blade guard.

Operational Controls:

  • Two-hand controls (both hands required, keeps hands away from danger zone)
  • Hold-to-run controls (requires continuous activation)
  • Proximity sensors (detects workers, stops machine)

Presence sensing system Figure: Light curtain presence sensing system

  • Speed limiters, load limiters

Emergency Stops:

  • Readily accessible
  • Clearly identified (red mushroom button)
  • Stops machine immediately

Emergency stop button Figure: Typical emergency stop button

Isolation:

  • Lockout/tagout for maintenance

Lockout with multiple locks Figure: Example of lock-out with tag and multiple padlocks

  • Isolation of electrical, hydraulic, pneumatic, mechanical energy
  • Dissipation of stored energy (springs, pressure, suspended loads)

Level 3: Administrative/PPE

  • Safe work procedures
  • Training and competency assessment
  • Permits for high-risk plant operations
  • Exclusion zones around operating plant
  • Pre-start inspections
  • PPE (hearing protection, hi-vis, hard hats, safety boots)

4. Maintain and Review​

  • Regular inspections (daily pre-start, periodic detailed)
  • Preventive maintenance schedules
  • Competent person conducts maintenance
  • Record keeping
  • Review after incidents or near-misses

Mobile Plant Safety​

Separation of Vehicles and Pedestrians​

Principle: Keep people and moving vehicles apart.

Controls:

  • Dedicated pedestrian walkways (physically separated)
  • Exclusion zones (barricades, signage)
  • Traffic management plan
  • Designated crossing points
  • Spotters for reversing/confined areas

Example: Fenced walkways on construction site separate workers from vehicle routes.

Proximity Detection Systems​

  • Sensors detect workers near plant
  • Alerts operator (visual/audible warning)
  • May automatically stop or slow plant
  • Useful for excavators, trucks with blind spots

Visibility​

  • Reversing cameras and monitors
  • Mirrors and visibility aids
  • High-visibility clothing for workers
  • Flashing beacons on plant
  • Reversing alarms

[!warning] Reversing Vehicles Reversing causes many injuries/fatalities. Eliminate reversing where possible, use spotters where unavoidable.

Rollover and Tip-Over Protection​

  • ROPS (rollover protective structures)
  • Seatbelts (must be worn in ROPS-equipped plant)
  • Operating within load ratings and stability limits
  • Level, stable ground conditions
  • Avoid slopes, edges, underground voids

Quad Bikes:

  • From 11 October 2021, all new and imported second-hand general use quad bikes must be fitted with an operator protective device (OPD) to protect riders in the event of a rollover.

Lifting Operations​

Before Lifting​

  • Plan the lift (load weight, lift path, hazards, exclusion zone)
  • Select appropriate equipment (crane capacity, rigging)
  • Inspect lifting equipment (cranes, slings, shackles)
  • Brief all involved (crane operator, dogger, rigger, workers)
  • Establish exclusion zone (no workers under suspended loads)

During Lifting​

  • Competent dogger directs crane operator
  • Clear communication (hand signals, radio)
  • Lift smoothly (no jerking or swinging)
  • No workers under suspended load
  • Secure load against wind, movement

Rigging and Slinging​

  • Calculate load weight
  • Select correct slings (capacity, condition)
  • Inspect slings before use (cuts, wear, damage)
  • Use correct hitches and fittings
  • Ensure load balanced and secure

Elevated Work Platforms (EWP)​

Types:

  • Scissor lifts (vertical)
  • Boom lifts (articulated/telescopic)
  • Mobile and stationary

Safety Requirements:

  • Licensed operators (boom-type >11m vertical)
  • Pre-start inspection
  • Level, stable ground (use outriggers if fitted)
  • Guardrails intact on platform
  • Harnesses required for boom-type (anchor to platform)
  • Avoid overhead hazards (powerlines, structures)
  • Do not exceed platform load rating
  • Lower platform when traveling

[!warning] Powerlines Maintain safe distances from powerlines. De-energize lines or use insulated/non-conductive equipment where work near powerlines unavoidable.

Scaffolding​

Licensing:

  • Basic scaffold licence: Scaffolds up to 4 meters
  • Intermediate scaffold licence: All scaffolds
  • Advanced scaffold licence: Design and inspection of scaffolds

Safety Requirements:

  • Designed for loads (live load, wind load, materials storage)
  • Erected by licensed scaffolder
  • Inspected before use and regularly
  • Tagged (green tag = safe to use, red tag = unsafe)
  • Edge protection (toe boards, mid-rails, handrails)
  • Safe access (ladders, stairs)
  • Stable foundation (base plates, mud sills)
  • Tied to structure (prevent movement/collapse)

See Construction Work for detailed scaffolding guidance.

Plant Registration​

Certain high-risk plant must be registered:

  • Cranes (various types)
  • Hoists
  • Pressure vessels and boilers
  • Gas cylinders

Purpose: Ensures design verified, item inspected, safe to operate.

Inspections and Maintenance​

Pre-Start Inspections (Daily)​

Operator checks:

  • Damage, leaks, loose parts
  • Safety devices functioning (guards, emergency stops, alarms)
  • Fluid levels, tire pressures
  • Lights, indicators, controls

Record findings, report defects, do not use defective plant.

Periodic Inspections​

Competent person conducts detailed inspections at intervals based on:

  • Manufacturer recommendations
  • Regulatory requirements (e.g., cranes, hoists)
  • Risk assessment

Maintenance​

  • Follow manufacturer maintenance schedules
  • Use qualified technicians
  • Keep records (maintenance log)
  • Ensure isolated before maintenance
  • Test after repairs before returning to service

Practical Construction Example​

Scenario: Using 20-tonne excavator for bulk excavation

Hazards Identified​

  • Rollover on sloped ground
  • Striking workers or other plant
  • Contact with underground services (gas, electricity)
  • Noise and vibration

Controls Implemented​

Engineering:

  • Excavator equipped with ROPS and seatbelt
  • Proximity detection sensors installed
  • Reversing camera and alarm

Administrative:

  • Licensed operator (verified before operation)
  • Service location completed (Dial Before You Dig)
  • Services marked on ground
  • Exclusion zone 5 meters around excavator (barricades, signage)
  • Traffic management plan (separate vehicle and pedestrian routes)
  • Pre-start inspection completed and recorded

PPE (for nearby workers):

  • Hard hats, hi-vis, safety boots, hearing protection

Maintenance​

  • Daily pre-start checks
  • 250-hour service completed (recorded in log)
  • Hydraulic hoses inspected (no leaks or damage)