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Employee handbook and
Safe Work Instructions
Manual
Date: 27/2/2014
Safe Work Instructions Manual
Page 3
This Manual contains the Safe Work Instructions for employees of:
This manual contains the minimum standards that must be followed by all employees.
Please read this manual and the SWI’s, ask questions if you are not certain on any issue. Your Manager / Supervisor will
discuss / demonstrate the general Safe Work Methods for completing each task and discuss and observe your compliance
with the Company Safety and Environmental rules contained in this manual during your induction.
Please Complete the Form at the back of this manual and return it to your Manager/ Supervisor once you have read/
understood this document.
REMEMBER THAT IF YOU FEEL THAT THE WORK IS UNSAFE, DO NOT PROCEED UNTILL YOU HAVE RESOLVED
THE SAFETY, QUALITY AND ENVIRONMENTAL CONCENRNS WITH YOUR SUPERVISOR / CLIENT.
If these standards can not be applied or if changes are required or new safety or other issues arise or procedures can not
be followed ,contact the Manager (or your Employee Health and Safety Representatives) so new or amended SWI’s or site
specific instructions can be issued.
Version Number No 001
Issued to: (Employees name)
_________________________________________________
Date of issue
_________________________
SysTec
Technical Management Services
© 2011
Disclaimer
his instruction manual has been prepared by SysTec Occupational, Health, Safety and Environmental Consultants.
Any representation, statement, opinion or advice expressed or implied in this document is made in good faith, but on the basis that SysTec P/L and its employees are not liable (whether by reason of
negligence, lack of care or otherwise) to any person for any damage or loss whatsoever which has or may occur in relation to that person taking or not taking (as the case may be) action in respect of any
representation, statement, opinion or advice referred to in this document
 2006 No part of this document may be reproduced by any means without permission of SysTec Pl Technical Management Services PO Box 350 Northcote Victoria 3070
Contact us on systec@systec-pl.com.au
Safe Work Instructions Manual
CONTENTS
Introduction.............................................................................................. 5
Safety Relies on a Cooperative Effort ................................................ 5
OCCUPATIONAL HEALTH ~ SAFETY POLICY ............................... 5
Company Roles and Responsibilities ..................................................... 7
Safety “Tool Box” Consultation Meetings ......................................... 10
What to do if there is a safety issue at work or on site ..................... 11
Procedure for Safety Issue Resolution ............................................. 11
Stop Work ......................................................................................... 11
RISK MANAGEMENT PROGRAM ....................................................... 12
OCCUPATIONAL REHABILITATION PROGRAM........................... 12
COMPENSATION AND REHABILITION POLICY ........................... 12
General Conditions of Employment ...................................................... 13
Disciplinary Action ............................................................................ 13
Disciplinary Procedure ...................................................................... 14
Drugs and Alcohol ............................................................................ 15
SWI 1 PPE Issue and Use .................................................................... 17
SWI 2 Working Around Above and Below Ground Assets ................... 21
SWI 3 Electrical Safety.......................................................................... 25
SWI 4 Confined Space and Restricted Space Entry ............................ 27
SWI 5 Site Establishment and Housekeeping ...................................... 30
SWI 6 Prevention of Falls from Height/ Prevention of Falling Objects . 32
SWI 7 Manual Handling ........................................................................ 39
SWI 8 Using Hand and Power Tools and Pressurised Equipment....... 41
SWI 9 Using or Contact with Hazardous Substances .......................... 42
SWI 10 Danger Tag and Lock out Systems.......................................... 44
SWI 11 Use of Mobile Plant .................................................................. 45
SWI 12 Hot Work (Welding, Braising, Cutting) ..................................... 48
SWI 13 Dealing with Accidents, Incidents and Emergencies ............... 54
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Safe Work Instructions Manual
Introduction
As an employee, manager, or supervisor involved in the construction or service industry there will be times when you will be
required to work in situations or with materials which are potentially hazardous.
This induction program has been designed to provide you with general information that can help you identify common
workplace hazards, to make informed assessments about hazards and risks at work and to reduce the likelihood of you
being injured or others being injured as a result of your actions.
If you are unsure of anything contained in the induction program, please ask the manager or supervisor.
Safety Relies on a Cooperative Effort
Provision of a safe workplace is a management responsibility, however the safety effort also relies heavily on the personal
attitudes of employees and your willingness to co-operate and participate in conforming to standards, reporting issues and
participating in the management of the factors that lead to accidents and incidents at the work place.
OCCUPATIONAL HEALTH ~ SAFETY
POLICY
1/ July 08
The following Occupational Health, Safety Policy has been approved and endorsed by the Company Director.
We believe that Occupational Health and Safety is vital for the overall efficiency and success of our company
Accordingly, our aim is to promote our business in a way that protects the safety of employees, contractors, customers and
the public.
The company recognises that active participation of every employee is essential to achieving a workplace free of accidents,
injuries and illnesses. With the assistance of all employees, we will strive to continually identify, eliminate or manage
workplace hazards and risks associated with our activities.
The Company also recognises that rectifying unsafe working conditions is management’s responsibility and any situation
considered unsafe should not be permitted to proceed until the risks have been assessed and appropriate measures have
been taken.
Accordingly, it is our policy to:

Achieve zero injury rates

Provide safe systems of work, adequate welfare facilities, Information and appropriate training to our employees


Comply with applicable laws and national / industry standards. Where standards do not exist develop internal
rules and standards necessary to protect the safety of employees and the public
o
Continually inspect, maintain and monitor plant and equipment and the work place
o
Stress to all personnel at every level, their role, responsibility and accountability for safe performance
Operate with authorities and the community in the development of standards aimed at further protecting
employees, sub contractors, customers and the public.
Authorised by the CEO. ______________________________
Safe Work Instructions Manual
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LEGISLATION
It is FE Welding’s policy that the work we conduct complies with all State laws. The key laws that apply to our operation
include:
- The Occupational Health and Safety Act (2004),
- Dangerous Goods Act (1985),
- Accident Compensation Act (1985).
- The Gas Safety Act (1997)
- The Electrical Safety Act (1998) and the:
- The Environment Protection Act (1970)
Administration of the Law
Work Safe has primary responsibility for administering health and safety laws in Victoria, including:
- The OHS and Dangerous Goods Acts and their Regulations
- Work Safe field officers (inspectors) are authorised to enter workplaces at any time and issue instructions and notices
relating to the safe conduct of work. It is important to comply with all instructions issued by the VWA inspectors.
The Gas Safety Act and the Electrical Safety Act
- The Energy Safe Victoria administers all legislation relating to the safe installation and use of gas and electricity.
Inspectors are authorised to enter a domestic or work site and issue instructions and notices
The Environment Protection Act
- The Environment Protection Authority (EPA) has responsibility for regulating Environmental discharges and disposals.
Officers may enter a worksite and direct actions to minimise or clean up spills or emissions and dispose of prescribed
wastes.
WHAT ARE YOUR RESPONIBILITIES?
Employers Legal Duties
The legislation requires employers (those people under general control of the operation, whether they are the owners or not)
to:
- Provide and maintain safe systems of work;
- Arrange safe systems of work with plant and substances;
- Provide a safe working environment;
- Provide adequate welfare facilities;
- Provide information, instruction, training and supervision
An employer shall, so far as is reasonably practicable:
- Monitor the health of their employees;
Safe Work Instructions Manual
Page 7
- Keep information and records on health and safety of employees;
- Employ qualified persons to advise on health and safety of employees;
- Nominate an appropriate person as the employer’s representative in OHS matters
- Monitor conditions of the workplace;
- Provide information to employees (in appropriate languages), including names of persons to whom inquiries or
complaints may be directed
Employee Legal Duties
While at work, employees must:
- Take reasonable care for your health and safety and the safety of anyone else who may be affected by your actions;
- Co-operate with your employer (and principal contractor) and comply with any requirements imposed by the law;
- Not wilfully or recklessly interfere with or misuse anything provided in the interests of health and safety;
- Not wilfully place at risk the health or safety of others
Company Roles and Responsibilities
Managing Director
The Managing Director is ultimately responsible for the implementation and maintenance of the company's safety system and
programs.
The Managing Director has the following responsibilities:
- Provision of a healthy and safe workplace
- Authorising and distributing the company's OHS Policy
- Allocating specific responsibilities to personnel.
- Ensuring adequate resources are available to meet health and safety obligations as well as legislative requirements: (if
necessary by employment of external consultants).
- Ensuring training is given to employees and sub contractors working on their sites.
- Ensuring incidents and injuries are reported and investigated where appropriate
- Monitor company injury, incident and dangerous occurrence records; and
- Ensure all reportable illness, injuries and incidents are notified to the appropriate authorities, e.g. Work Cover, Office of
Gas Safety, Office of the Chief Electrical Inspector, Insurance Organisations and the EPA.
Safe Work Instructions Manual
Page 8
Supervisors/ Project Managers
The Managing Director (MD) may delegate the responsibility for administering site safety arrangements to nominated
personnel – (or a consultant). Project Managers / Supervisors have the following responsibilities:
- Implementing the company Occupational Health Safety and Rehabilitation procedures;
- Observing all OH&S requirements and statutory rules and regulations;
- Ensuring that all works are conducted in a manner safe that is and without risk to employees’ health and safety;
- Planning to do all work safely;
- Providing advise and assistance on OH&S to all employees;
- Participating in the planning and design stages of trade activities;
- Ensuring current OH&S and other relevant legislative requirements are met in the workplace;
- Identifying OH&S training programs in advance and allowing for employee/s identified as requiring training to attend the
training;
- Actioning safety reports and carrying out workplace inspections;
- Preparing and participating in safety meetings and safety programs;
- Facilitating the preparation of Work Method Statements, Work instructions and Job Safety Analysis for the trade;
- Preparing and conducting new employee and site specific inductions;
- Insisting on and ensuring safe work practices are maintained;
- Investigating hazard reports and ensuring that corrective actions are undertaken;
- Conducting toolbox talks and team briefings;
- Participating in accident/incident investigations;
- Leading by example;
- Supervising and ensuring compliance with Safe Work Instructions;
- Stimulating a high level of safety awareness at all times;
- Where appropriate take responsibility for resolving OH&S issues;
- Facilitating the maintenance of all records as required under this Safety Plan.
- Ensure the requirements of legislation are met, and keep company personnel informed of changes to legislative
requirements;
- Ensure management, supervisors and sub contractors (where necessary), are informed on all matters relating to Client
requirements and OH&S and Environmental Legislation.
- Coordinate day-to-day health and safety matters; and
- Attend Company meetings.
Safe Work Instructions Manual
Page 9
OH&S Representative [If elected]
An OHS Representative can:
- Assist the Job Supervisor to develop and implement the Occupational Health, Safety and Rehabilitation procedures
- Communicate safety performance to the Job Manager;
- Provide advice and assistance on OH&S to all employees;
- Monitor OH&S legislative requirements for the trade;
- Monitor compliance with Safe Work Procedures and Instructions ;
- Review safety reports and inspections;
- Prepare and participate in safety meetings and programs;
- Insist on correct and safe practices at all times;
- Assist with job safety inductions and new employee inductions;
- Investigate and develop new OH&S initiatives for the trade;
- Assist in the conduct of accident/incident investigations;
- Lead by example and promote OH&S at every opportunity;
- Stimulate a high level of safety awareness at all times;
- Participate in regular workplace inspections and ensure that any improvements resulting from such an inspection are
actioned in the required time frame.
Employees
Employees are responsible for ensuring their safety and the safety of others affected by their actions on the project.
Duties include:
- Communicating with the Job Supervisor on matters relating to health and safety;
- Reporting of all accidents, incidents and hazards;
- Wearing of appropriate supplied personal protective clothing and equipment;
- Using and maintaining all safety equipment and plant in the method for which it is meant to be used;
- Refraining from the use of drugs or alcohol, as per the company policy;
- Assisting with the investigation of workplace accidents and incidents;
- Following safe work methods, procedures and practices at all times;
- Not endangering the health and safety of themselves or others in the workplace;
- Attend and actively participate in safety meetings, inductions, toolbox talks, training and safety awareness sessions;
- Obeying reasonable instructions
- Adopting and actively participating in any rehabilitation and return to work programs following injury to personnel;
- Abiding by all Legislative Acts and Regulations as required to perform the work safely
Safe Work Instructions Manual
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- Be suitably dressed for the particular working environment or activities carried out,
- Wherever applicable, ensure that all tools and equipment are in good condition and report any defects to the Manager
immediately;
- Report all incidents or accidents;
- Be aware of the emergency evacuation procedures.
Workplace Consultation
The OHS Act sets out three methods of consultation at the work place:
- Health and Safety Representatives (HSR) - elected by employees and represent the interests of that group of
employees (termed a designated work group). The HSR deals with issues on a day to day basis with the nominated
management representatives. Employees may request any employer to form a Designated Work Group (usually site
based in construction) and conduct an election for a Health and Safety Representative.
- A Health and Safety Committee, which concentrates on joint health and safety management issues covering the whole
workplace. Health and Safety committees are not mandatory under the Act, however the employer must have a Safety
Committee if requested to do so by the Health and Safety Representative.
- Direct consultation with employees
Safety “Tool Box” Consultation Meetings
FE Welding conducts regular site meetings between employees, and sub contractors where they are employed on
commercial sites. When contracted to larger organisations, employees will attend the client tool box meetings.
Where formal tool box meetings are not appropriate, regular or one on one discussions on safety or other issues will take
place at regular intervals.
Toolbox meetings are used to:
- Communicate information on site specific hazards / risks and safety / environmental protection arrangements
- Report progress on health and safety issues
- Ensure employees are involved with identifying, and assessing localised work place hazards and the development of
safety precautions
The names of Your Health and Safety Representatives are detailed on the Contact Card at the end of this manual:
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Safe Work Instructions Manual
What to do if there is a safety issue at work or on site
The following procedure should be used if you identify a safety issue that can not be personally resolved.
Procedure for Safety Issue Resolution
Start
Issue Noted/ Make
safe and report
Issue Resolved
Yes
Record
No
Is There a HSR/
Site HSR/
Committee?
No
Nominate a
spokesperson/
Union rep or call
Workcover
Yes
Stop work Call
WorkCover
Yes
Immediate Risk?
The Law allows that where all
attempts to resolve an issue
are still unsuccessful and
where there is a risk of
serious and imminent harm,
an employee or elected
Health and Safety
Representative may stop
work and notify a Work Safe
Inspector
No
Issue a PIN
Issue
resolved?
No
Call WorkCover
Yes
Record
End
Stop Work
Employees may refuse to work where they have a reasonable fear that to continue working may expose them or others to
risk of injury or harm.
The legislation does not simply allow you to down tools and walk out, however.
If you believe that you are at risk and because of that risk, to stay on site places you in danger, you must:
- Notify us (the employer) immediately
- Accept reasonable alternative work until normal duties can be resumed
You are still eligible to receive the same pay and allowances as would apply if you had been able to carry out your normal
duties.
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Safe Work Instructions Manual
COMPENSATION AND REHABILITION
POLICY
1/ July 08
Our Company is committed to providing a safe and healthy workplace for all workers. In the event of a work related injury we
will take steps to ensure the injury does not recur. Should one of our workers incur a work related injury and is unable to
continue normal work we will provide the necessary assistance for them to remain, or return to work as soon as it is safely
possible. We will do this through risk management and occupational rehabilitation. Our commitments are as follows:
RISK MANAGEMENT PROGRAM
We will:
- Take all practicable steps to identify, assess and control risks to workers & visitors
- Encourage the early reporting of any symptoms of any work injury or disease
- Investigate all incidents, to identify their cause(s) and prevent their recurrence
- Comply with all our legal obligations, including notification of incidents to WorkSafe Victoria when required.
OCCUPATIONAL REHABILITATION PROGRAM
We will assist our injured workers to remain at work or return to work at the earliest opportunity. Specifically our RETURN
TO WORK POLICY is that:
- Return to work planning will commence as soon as possible after an injury, consistent with medical advice.
- Remaining at or early return to work following an injury is a normal expectation of this workplace.
- Treatment, return to work activities and any reasonably necessary occupational rehabilitation services will begin as
soon as they are necessary.
- An injured worker requiring an occupational rehabilitation service may be provided with a choice of the provider where
they are available
- Suitable employment, including modified or alternate duties, consistent with medical opinion, will be made available to
all injured workers.
- An individual return to work plan will be established with any worker who is unable to work for 20 calendar days or
more.
- Consultation and communication with all workers in the development and review of our occupational rehabilitation
program and individual return to work plans will occur.
- Confidentiality of worker's information obtained during their return to work or while undertaking occupational
rehabilitation services will be maintained.
- Participation in a return to work plan will not, of itself, prejudice any injured worker.
Policy Authorised by …………………………………
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Safe Work Instructions Manual
IF YOU SUFFER A SERIOUS INJURY- CLAIMING WORKERS
COMPENSATION
Should you suffer a significant or major injury at work, you should be entitled to workers compensation
As an “injured” employee, you will receive weekly injury compensation payment and be reimbursement of any medical
related expenses.
If you are seriously injured at work the following steps must be taken, in order:
- Contact your employer to complete an accident report so it can be lodged as a workers compensation claim under the
Accident Compensation Act. This must be done on the same day that the accident occurs or as soon after the event as
is practicable.
- Obtain a First Medical Report Form from a Medical Practitioner (Doctor).
- Keep all doctors’ certificates and accounts for treatment and give them to the employer.
- If you have been off work for any injury whatsoever, whether work related or not, you must not return to work without
submitting proper medical clearance.
- Where the medical practitioner recommends, you may be required to return to work on alternate duties.
- If you return to work, you are entitled to the same average pay and conditions as normal.
- If you refuse to accept alternate duties, you may loose your compensation entitlements.
Note
Failure to report an accident or failure to follow the above procedures may lead to the full or partial
rejection of your claim for compensation.
General Conditions of Employment
All employees must follow the safety arrangements established at site. If you are in any doubt, at any time, as to the safety
of a particular task or workplace, it is your responsibility to check with your supervisor before proceeding.
Disciplinary Action
If an employee or sub contractor wilfully engages in acts that create or increase risks to themselves or others, or engage in
theft, wilful damage, physical or verbal violence or fails to perform their duties in accordance with instructions, The Manager
will follow the Disciplinary procedure shown on the next page.
Where the three cautions are given within a period of 12 months the, employee or contractor will be informed that one
further breach will result in termination.
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Safe Work Instructions Manual
Disciplinary Procedure
Start
Unsatisfactory
performance or unsafe
Action by employee or
sub contractor noted
Manager
Counsels / Formal
Verbal Warning
Action
Continues
No
End
Yes
Document and
give a copy to
employee/
Contractor
First written
Warning
Action
Continues
No
End
Yes
2nd Written
Warning
Action
Continues
Yes
Termination
End
No
End
Safe Work Instructions Manual
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Drugs and Alcohol
The purpose of this policy is to maintain a work environment free from the effects of the use of alcohol and drugs
The Company insists that no employees are to commence work, or return to work while under the influence of alcohol or
drugs.
To help promote a safe and healthy working environment, the company;
- Observes a no smoking policy in all premises, including company vehicles,
- Provides the services of an Employee Assistance Program to assist employees in the treatment of alcohol or drug use
problems,
- May subject employees to drug and alcohol testing,
- Requires that employees who use prescription drugs to check with their doctor to determine if the use of the drug will
impact on work performance. If so, the information must be provided in writing to their manager,
- Requires that vehicles not be driven by employees, or others, under the influence of alcohol or drugs in excess of the
legal limits, Medical Practitioners advice, or product advice. No liability will be accepted for any damage to a company
vehicle; injury to any person, or damage or injury to any third party, incurred while the driver of the vehicle is in breach
of this policy or the law.
- Employees will not be treated harshly, unfairly or unjustly by this policy. All reasonable efforts will be made to ensure
personal information remains confidential.
Standards of dress and behaviour
An employer may set and enforce standards of dress, appearance and behaviour for employees that are reasonable having
regard to the nature and circumstances of the employment.
Harassment
The Australian Human Resources Institute defines harassment as: “behaviour that is uninvited and unwelcome, and is
offensive and makes the person targeted feel humiliated or intimidated, or creates a hostile working environment. It does not
usually include behaviour such as genuine compliments or mutually acceptable physical contact.”
Some examples of harassment include:
- Indecent assault
- Circulation of offensive material that is homophobic, racist, sexist, etc.
- Verbal abuse
- Jokes
- Repeated unwanted and deliberate physical contact
- Inappropriate questioning about one’s private life
What to do
There are many equal opportunities, anti-discrimination bodies that specialise in this area. But first you may want to try to deal
with the problem yourself in an informal manner. Although it may be uncomfortable, you could:
- Tell the person who is harassing you that their behaviour offends you
- Make it clear that their behaviour has to stop or you will take the matter further
- If you do not want to confront this alone, contact your employer
Safe Work Instructions Manual
Safe Work
Instructions
Page 16
Safe Work Instructions Manual
Page 17
SWI 1 PPE Issue and Use
Objectives and Targets
All personnel must wear relevant Personal Protective Equipment (PPE) when other methods of preventing injury are
inadequate, or where:
- Indicated in Work Method Statements or in Safe Work Instructions
- The employee determines hazards exist
- On all Client or Customer sites where prescribed PPE is mandatory or where the need to wear it is signposted.
- Specific PPE is identified on a JSA or Permit to Work Clearance Certificate.
Employees will be consulted directly, or at safety consultation meetings before new types of PPE are purchased.
ALL PPE SHALL MEET LEGAL REQUIREMENTS AND AUSTRALIAN STANDARDS AS A MINIMUM.
Basic PPE Issue
The Manager will issue employees with the following at the time of employment:
- Overalls or similar work clothing.
- Steel capped safety footwear.
- Safety glasses/ Goggles/ Full face shields as required.
- Helmet – as required
- High Visibility Vests
- Hearing protection (a choice of Ear Muffs and/or Hearing Plugs)
- Respirators and breathing apparatus - as required
- Danger and Out of Service Tags, Locks and hasps
- Gloves (riggers, solvent, leather palm) – as required
Special Process PPE
Special process PPE includes (issued by the supervisor as required)
- Harnesses, Fall arrest or restraint systems, attachments and lanyards
- Welding gloves, aprons, spats, goggles and shields or other equipment specific to a project or task
Overalls / Work Clothes
- Overalls or work clothes will be re-issued when sufficiently worn.
- Overalls/ Clothes must be regularly laundered and kept in a good state of repair at all times
Safe Work Instructions Manual
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Safety Glasses / Full face Visors or Goggles (See the quick reference
Chart)
Must be worn on site in all areas designated by signage or when working in situations or with materials, vapours etc may
enter eyes.
- Goggles must be worn when using chemical and hazardous substances that may splash or enter the eyes when
decanting and during application
- Employees who wear prescription glasses and are required to work in mandatory eye protection areas shall be
supplied with prescription safety lenses as per AS 1337. Employees shall provide a current prescription prior to issue
- Excessively scratched or damaged eye protection should be reported and replaced.
THE COMPANY WILL ACCEPT COST OF LENSES AND STANDARD SAFETY FRAME.
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Safe Work Instructions Manual
Helmets
Helmets must be worn wherever there are electrical or overhead hazards. Helmets will be replaced every 3 years or
when subject to damage. Helmets must not be marked, cut or written on.
High Visibility Vests
High Viz Vets (or Fluro shirts) must be worn on all commercial sites, where indicated, when working on roads or public
areas, on, in, or around mobile plant or in excavations.
Fluro shirts or Vests MUST BE REPLACED WHEN THE FLURO
STIPS OR QUALITY FADES AND NO LONGER PROVIDES A
CLEAR VISIBLE WARNING TO OTHERS
The vest check picture is a guide to replacement
Hearing Protectors (a choice of Ear Muffs and or Hearing Plugs)
Hearing protectors or ear plugs shall be made available to employees and must be used at all times in noisy areas. The
following chart provides a guideline to noise levels associated with common activities. REMEMBER IF YOU CAN NOT
HEAR NORMAL SPEECH AT A DISTANCE OF ONE METER THE AREA MAY BE TOO LOUD AND YOU CAN CAUSE
DAMAGE TO YOUR HEARING OVER TIME
Hearing plugs will be made available at all project sites and in
company vehicles. Employees using hearing plugs must ensure
that hands are clean when inserting plugs. Plugs should be
disposed of after one application.
- All personnel provided with hearing protectors must have biannual hearing tests. These will be organised by the company
- Employees are responsible for regular cleaning of earmuffs with
mild soapy water in accordance with the manufacturer’s
instructions.
Safe Work Instructions Manual
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Respirators and Breathing Apparatus
Half face respirators, paper particulate respirators and/or appropriate half-faced organic vapour
cartridge respirators will be supplied to all employees. Replacement cartridges are available
from the Manager.
- Disposable masks (P2) shall be made available at all project sites and must only be used
once.
- Where a respirator is used which relies on facial seal then the user must be clean shaven.
- Organic vapour filters shall not be used in atmospheres deficient in oxygen or atmospheres
with toxic gases
- Where facial hair prevents an adequate seal, employees must contact the Manager and an
investigation of other types of suitable respirators will be undertaken
Gloves
A choice of riggers, leather palm, PVC or latex gloves (for solvent cement) will be made available to employees and
should be used when hand hazards are present.
- The Manager will ensure Chemical gloves are selected based on the Hazardous Substances Risk Assessment and
MSDS. These will be made available for use when handling Hazardous Substances or Dangerous Goods
- Wearing of Gloves is mandatory when identified as a requirement in the Work Method Statement or when chemical or
physical hazards are present.
- Gloves must not be washed or recycled.
Maintenance – Cleaning and Replacement
Employees are responsible for:
- Keeping all standard issue equipment clean and in good repair
- Keeping adequate spares (consumable parts such as filters and hearing protectors) in vehicles
Where equipment becomes damaged or is outside its test date, employees must contact the Manager for replacement
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Safe Work Instructions Manual
SWI 2 Working Around Above and Below Ground Assets
Objectives and Targets
- Assets (above ground- below ground) are identified before work commences
- Clearances are granted by the asset owner where required before work commences
- Spotters are present when work occurs within a no go zone.
- PPE is worn at all times.
Pre Start Site Investigation
Before any work is carried out it should be established where all overhead and underground assets are located.
If work is to be conducted near assets a Work Method Statement/ JSA must be completed, permission granted and safety
instruction given to all personnel on the job.
Over head Power lines - No Go Zones
When work takes place around power lines you must follow the “Rules for Work around High Tension and Power lines”. The
rules specify the NO GO and SPOTTER REQUIRED ZONES for constructing scaffolding or operating cranes, hoists or
excavating equipment.
NO GO ZONES FOR SCAFFOLDS
Power lines on Poles
Horizontal
Clearance
Vertical Clearance
4.6 m
(sides)
5 m (above and below)
NO GO ZONES FOR ELEVATED WORK PLATFORMS, CRANES,
EXCAVATING EQUIPMENT, CONCRETE PLACING BOOMS
Horizontal
Clearance
Vertical
Clearance
Power lines on Poles
3 m (sides) 5 m (below,
no where
above)
Power lines on Towers
8 m (sides)
Spotter Zone
3m-6.4m
(either side, bellow
and anywhere
above)
10 m
8 - 10 m (either
(below, no
side, bellow and
where above) anywhere above)
If work is to be performed within a NO GO ZONE and within the minimum distances contact the Manager and DO NOT
COMENCE WORK until the Asset owner gives written authorisation, a spotter is present and a Work Method Statement/ JSA
is conducted.
If cranes, hoists or excavating equipment are going to be used around power poles in Spotter Zones a trained and qualified
spotter must be present when work is carried out.
The spotter must be present at ALL times throughout the task and needs to be positioned to observe and warn. If the plant
design envelope is inside the electrical no go zone it should be controlled with non-conductive tag lines.
Safe Work Instructions Manual
Page 22
Underground Services No Go Zones
If work takes place around underground assets the following rules apply
If Work must take place in a No Go Zone area the following must be
followed
- Dial before dig and obtain the plan
- Inspect the site
- Identify personnel or organizations that may be affected by the work
- Identify plant set down areas
- Identify traffic management plan requirements
- Identify areas for barricades, arrangements for erecting temporary
hoarding, erection of scaffolding or bracing, etc.
- Check for asset locations
o
Prior to any excavation work, check at least 100m along the footpath in each direction and around nearby
corners for indications of existing assets. These include:
o
indicators or markers for underground assets, drainage pits and manhole covers
o
damaged footpaths, driveways or depressions which may indicate the presence of a trench
o
cables running up a pole
o
overhead cables near the worksite
o
control cabinets
o
no overhead wires to a building or premise
o
above ground connection cabinets, transformers for cathodic protection on power poles, light poles without an
overhead service, service pits for gas, water, electricity, communications, sewerage and drainage connections,
down pipes or vent poles, underground storage tank fill points and venting systems,
o
kerb markings
o
water valves
o
fire hydrants and plugs
o
sprinkler systems
Safe Work Instructions Manual
Page 23
o
road repairs
o
trap doors or access-covers for access to underground electricity substations,• access to cable jointing pits or
tunnels,• access to sewerage or storm water trunks,• access underground gas regulators, siphons and valve
assemblies,• access to shafts,• link box pits, oil tank pits and other ancillary underground pits, domestic service
pits, gas or water meters, electricity pillars and meter boxes
o
any other signs out of character with the surrounding area such as a clearing for an easement.
o
If such indications exist, the asset must be located by hand or service detectors and pot holing or another
method nominated by the asset owner.
Plan or drawing reading
When reviewing the information:
- identify the streets or buildings nearby and position yourself so the streets correspond with the plan/s
- use the scale and measurements indicated on the plan/s to pinpoint your exact location - remember drawings may
NOT be to scale
- many plans reference the asset location from an adjacent property alignment
- determine if measurements are metric or imperial, or a combination of both
- identify nearby pipes or cables and mark their recorded location
- cross-reference any supplementary plans or details
- identify any of the items listed below and assess their relationship to each other to determine if a measurement has
altered:
o
o
o
o
building lines
pits and poles
offsets
turning points
Note: Inaccuracies can and do occur, both on plans and in the ground. If in doubt, check with the asset owner. Never
guess or assume!
Asset owners’ plans show only the presence of some cables, pipes and plant. They only show their position relative to road
boundaries, property fences etc. at the time of installation and the utilities do not warrant or hold out that such plans are
accurate thereafter due to changes that may occur over time.
DO NOT ASSUME DEPTH OR ALIGNMENT of cables or pipes as these vary significantly.
Obtain all permits and permissions
It may be necessary to consult with some or all of the following:
- Vic Roads
- Councils
- Asset owners
- Adjoining property owners
Consideration may need to be given to:
- What to do with redundant assets, planed services
- Methods of protecting assets
- Levels
- Compaction and backfill materials
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Safe Work Instructions Manual
Work hours
- Temporary covers
- Provision of visual identification devices
- Operation of heavy plant over existing assets
- Provision of temporary footpaths , signage etc
Assets around poles
- Work should not commence within 10m of a SWER pole without instruction from the asset owner.
Vertical Boring
- Work within 500 mm of an asset (other than those in Table 1 ) the assets must be proved by hand and a minimum
clearance of 300 mm must be maintained. A lead bore should be used first
Directional Boring
- When boring across the line of the assets prove the asset by hand
- When boring under electrical assets it will be necessary to dig a slit trench to prove the direction and depth
Hand Excavation
- Potholing -once the general information cables has been obtained pot hole up the run to prove depth and direction
- While digging, it is important to dig with the blade of the shovel parallel to the cable route, especially where the cables
are direct buried i.e. not enclosed in a conduit.
Sometimes several potholes will need to be dug manually to determine the exact location of cables to avoid damage.
Table 1
TYPES OF UNDERGROUND
ASSETS
Minimum clearances for
individuals (A), and the
operating envelope of
plant and equipment (B)
Safety Controls required
Assets listed under the
Pipelines Act. (high pressure water, gas or
hydrocarbon)
3M
Must contact the Asset Owner
for specific conditions
All electricity conductors greater than 66kV 3 M
Must contact the Asset Owner
for specific conditions
All electricity conductors up to and
including 66kV
300 (A) 500 (B)
See specific requirements in the
Work Safe underground
guidelines and the precautions
Telecommunications Cables
300 (A) 500 (B)
Must contact the Asset Owner
for specific conditions
All gas pipelines other than those above
300 (A) 500 (B)
See specific requirements in the
underground guidelines
Water, Drainage & Sewerage pipelines.
300 (A) 500 (B)
Must contact the Asset Owner
for specific conditions
Safe Work Instructions Manual
Page 25
SWI 3 Electrical Safety
Objectives and Targets
- All electrical hand tools and leads are maintained in good order
- All equipment is tagged with a current tag
- Earth straps are fitted on gas/ water lines before cutting
Wiring, Switch boards, Control Panels and Appliances
- Temporary wiring on a site must be inspected every month
- The power supply to all electrical equipment must have RCD protection and be checked every month
- Temporary switchboards with RCD protected final sub-circuits must be used to supply all lighting and socket outlet
power.
- Temporary switchboards in general require:
o
A latching door or a non-removable lid;
o
rounded and smooth-edged access holes or a recess under the door for connection of extension cords to
switchboard mounted socket outlets;
o
At least one 15 amp socket outlet;
o
A weatherproof construction; protection against mechanical damage;
o
a stable stand or be fixed to a wall and post mounted switchboards must be coach screwed or bolted; and
reasonable frontal access to be maintained. A clearance of 1.2 metres is recommended.
Hand Tools and Leads
- Do not use hand tools or leads that do not have a current tag (every 3 months).
- Keep electrical leads and flexes from electrical tools clear of working surfaces, access ways, water, flammable liquids
or in areas of excessive heat
- Only use electrical tools and welders in accordance with the manufacturers instructions
- Report any unsafe electrical problem to the Site Manager / Supervisor.
- No extension cord should run from one floor to another on multi-level sites.
- Cords used around structural steel and sheet metal must be protected from possible mechanical damage.
- Cords should be raised on insulated stands or hooks to protect them from damage and to provide clear access for
personnel and vehicles.
- Cords should never run through water or be on the ground where mobile plant and machinery is used.
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Safe Work Instructions Manual
Maximum length of flexible extension cords
Rating of Flex
Max rated current of
type c circuit breaker
Min area of cable Max length
A
A
Mm2
M
10
20
20
1.0
1.5
25
35
15
20
32
32
1.5
2.5
25
25
40
20
32
32
2.5
4.0
30
50
Gas/ Water lines and Earth Straps
- Where main lines require cutting, always use earth straps as the pipe work provides a return electrical circuit to the
power source
- Do not remove earth stakes or earth connections from pipe work
A Danger Tag must be fitted to electrical circuits when isolated prior to
commencement of work (See SWI 10)
All electrical disconnections and reconnections must be performed by a licensed
electrician - Contact the Manager
Safe Work Instructions Manual
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SWI 4 Confined Space and Restricted Space Entry
IF YOU ARE UNSURE WHAT TO DO - DO NOT ENTER A RESTRICTED OR CONFINED SPACE
- CONTACT THE MANAGER
Objectives and Targets
- All potential confined spaces are identified prior to commencement of work
- Gas testing occurs before entry
- Permits are completed correctly before work commences
- Personnel entering confined spaces are trained and competent
Definitions
A confined space is defined as:
A space in any vat, tank, pit, bin, container, receptacle,
underground sewer, shaft, well, trench, tunnel, or other similar
enclosed or partially enclosed structure, where there is a risk or
engulfment or fire, if:
It has restricted entry or exit (that makes it physically difficult to
enter or exit), and
It is at normal atmospheric pressure and contains (or has potential to contain)
1.
An atmosphere that has a harmful level of any contaminant
2.
An atmosphere that does not have a safe oxygen level or
3.
Any stored substance, (except liquids), that could cause engulfment.
A restricted space is defined as:
Any task area that is difficult to get in or move around in. Restricted spaces DO NOT contain harmful substances or an
unsafe level of oxygen.
Examples of restricted spaces often can include: under-floor spaces, roof ceilings, spaces between plant, plant rooms,
etc.
General
Personnel must inspect the area and identify if the space is a confined space or restricted space.
- If the space is difficult to enter and likely to contain a harmful level of contaminant or lack of breathable air the space
must be treated as a confined space.
- All confined spaces should be sign posted, but this may not always be the case- if in doubt contact the manager and
or customer representative.
- Verify the work needs to be done within the Confined Space; if possible work should be performed from outside the
space.
If an area has been deemed a confined space, then only trained personnel using the correct equipment in accordance
with the following procedure should be allowed to enter the area.
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Restricted Space Entry
If the space is a restricted space:
- Look to improve access, e.g. cut access ways or look for alternate fixing or installation points
- If alternate access ways are not practical - clear obstacles
- Inform others in the area that you are entering the space, where practical, and make sure a spotter or assistance is
available
- Conduct a site-specific risk assessment (JSA) if energy sources or other non routine hazards exist, (e.g. electricity, or
gas services) are present
- Ensure adequate ventilation and lighting is present (DO NOT USE 240V lighting) – use low voltage lighting or battery
powered equipment, or torches
- Use appropriate Personal Protective Equipment
Confined Space Entry
Job set up
If the space is a potential confined space and entry to the space is required:
1.
A Confined Space Work permit must be completed prior to any work being carried out (The Manager will provide a
Permit to work Form)
2.
Where a customer has a Confined Space Entry Permit Procedure / Permit - staff shall use the customer procedures
3.
The Confined Space Permit shall be displayed at the access point at all times during work activities
4.
Confined Space Entry Permits shall be returned to the Manager on completion of work or expiry of the permit and
retained on the Job File for a period of at least one month
5.
A minimum of 3 personnel must be present at the entry at all times
6.
A person with a confined space entry certificate must perform a gas test using an instrument with a test
compliance certificate.
Pre Entry Requirements
1.
A WMS must be prepared prior to entry by those involved in the entry
2.
All sources of energy, e.g. materials entering the space, electricity, fluids or other materials must be prevented from
entering the space while the work is being carried out and all isolation points must be tagged (SWI 12 Danger Tag
and Lock Out Procedure)
3.
A Gas Test must be undertaken prior to entry and the results must be recorded on the gas test record section on
the Confined Space Permit to Work
4.
o
Gas tests should determine if the atmosphere is hazardous or likely to be hazardous (e.g. the oxygen level is
less than 19.5% or high levels of contaminant or flammable contaminant levels exceeding 10% LEL exist)
o
If a MSDS is available for the contaminant or materials being used these must be reviewed
Where possible clean the space of residual contaminants by washing and purging or mechanical ventilation and or
extraction
o
5.
NOTE Pure Oxygen or Gas mixtures with an oxygen concentration exceeding 21% shall not be used
Remove sources of ignition
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NOTE if flammable vapours, dusts or containments are present non sparking tools must be used
o
Provide all PPE, including Respiratory protection of the correct type and class (see SWI 01 PPE and the Work
Method Statement)- Contact the Departmental Manager
6.
A rescue system (harness and line) must be used by the person entering the space and attached to a stand-by
person. A third person should be positioned within hailing distance in the event of an emergency
7.
A reliable method of communication (e.g. radio communication, communication line etc) must be established
8.
The Emergency Response arrangements must be reviewed prior to entry
Examples of excavations with harmful contaminants that are confined spaces:
Trenches, shafts, tunnels, manholes, pits, sewer lines, underground pump stations or similar constructions connected to:
- Either an open sewer line, a previously live sewer line, a line which is to be opened or found to be broken or leaking; or
any other service line likely to generate a harmful level of any contaminant.
- Steel water mains or similar pipelines where:
o
Welding, cutting or other operations are carried out inside the pipeline that is likely to either create a harmful
level of contaminant or deplete oxygen in the atmosphere to an unsafe level.
- Shafts or tunnels being excavated to repair replace or break into any live or previously live sewer line.
b. Examples of excavations that have to be assessed on a case-by-case basis:
- Excavations where:
o
there is no sewer, stormwater, or gas line either exposed or open, or likely to be exposed or opened, but where
there may be leaking service lines nearby, harmful gases from decomposed material, or other sources being
released from the ground itself; or the presence of engine exhaust gases or the use of solvents or other
materials in the excavation may create a hazardous atmosphere.
- Stormwater drains, water mains, pits or similar excavations where there is:
o
a likelihood of either a contaminant entering and contaminating the atmosphere or a depletion of oxygen (for
example, in unused sections of large water mains, or an industrial area where large quantities of chemicals or
other contaminants are being manufactured or are in use).
- Any pit or tunnel that:
o
has not been connected to a live service line but is sealed from natural ventilation; or where solvents have
been in use for sealing pipes and a hazardous atmosphere may have built up; or where the curing of fresh
concrete may have reduced the oxygen level to below 19.5%.
- Shallow open shafts and trenches where:
o
there may only be a small quantity of contaminant in the atmosphere, for example, some household
connections to live sewer points, and where there may be good natural ventilation.
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SWI 5 Site Establishment and Housekeeping
Objectives and Targets
- Sites are inspected before work commences
- Site hazards are identified and safety measures are undertaken prior to work commencing
- First Aid and emergency response arrangements are verified as suitable for the job prior to work commencing
- Members of the public and other workers are protected from harm as work progresses
- All signage and barricades are erected prior to the commencement of work
- All tools are maintained in good condition
- Waste is removed from the site and disposed of in accordance with client or contract requirements or in the case of
hazardous waste to licensed sited authorised to process the waste
Site Inspections
Before the commencement of work the following site checks must be undertaken and the necessary controls put in place.
- Inspect the area access, egress emergency escapes, structure , public areas
- Check for asbestos, dangerous goods or hazardous substances stored in buildings, cellars or tanks
- Check for soil contamination - ground condition
- Slip trip fall hazards
- Identify the locations of possible underground services
- Check electrical wiring
- Check the condition and strength of roofs, floors, stairs, guarding, walls and structural members
- Check that the fire services are adequate and working
- Identify designated storage and parking areas
- Identify traffic conditions and traffic management plans
- Ensure adequate fencing and security arrangements are in place (where needed)
- Ensure all temporary services are installed, wiring is marked and all temporary supply boards are secured, labeled and
protected (where needed).
First Aid
- When working on a commercial site ensure there is an adequate number of First Aiders. Ensure a First Aid Kit is
available and all the necessary emergency phone numbers and contact list are present. (Including ambulance, police,
fire, doctor (medical centre), poisons 131126 and the WorkSafe Emergency response line)
Barricades, Signs and Notices
Where working around members of the public BARICADES AND SIGNAGE MUST BE USED:
- At a MINIMUM, witches hats must be used for all minor or short duration works.
- Where high risk works or longer duration works are undertaken a suitable physical barrier must be installed (CONTACT
THE MANAGER) e.g. A 1.8 meter chain mesh or hoarding should be erected in high traffic or public areas.
- All leads and hoses in areas that can not be barricaded and signed must be covered with a non trip barrier and
signage,
- Install exclusion barriers and signage around work areas,
- If loading or unloading near a public thoroughfare, ensure a traffic management plan/procedure is in place e.g.
Safe Work Instructions Manual
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- Signs/barricades
- Traffic spotter
Lighting
Ensure suitable levels of lighting exist in the work area, wherever possible use low voltage light sources, shade or wear
UV polarised glasses in conditions of glare
Work Areas
Maintain a high level of house keeping at all times. Task area condition is the employees responsibility
Emergency Response
Ensure:
- Fire fighting appliances and first aid kits must be accessible at all times
- Attend all principal contractor / client site inductions and follow all instructions as required
- Ensure you understand what to do in the event of an accident, fire or emergency and know were the evacuation
assembly points/First Aid and emergency equipment are identified on the site plan.
Tools and Equipment
- All tools and equipment must be inspected and maintained in good order – all Guards must be intact and good order
- Storage areas should be secure and all tools/ components should be stowed in a neat order.
- All components should be separated, accessible and compartments/storage areas should be free from waste items
Waste removal
Employees are responsible for removing waste from the job site to the appropriate storage containers.
All prescribed waste, biological waste to be removed (eg, sewage, lead, asbestos, radiation sources etc) must be
removed by a licence contractor, CONTACT THE MANAGER BEFORE WORKING OR REMOVING THESE
MATERIALS
Site Security
All sites should be left secure against unauthorised Access, and Theft.
All tools should be removed from the work area when personnel are not in attendance. All Access Equipment/ Mobile
equipment should be secured against entry and access. Keys should be removed if possible.
Safe Work Instructions Manual
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SWI 6 Prevention of Falls from Height/ Prevention of Falling Objects
Objectives and Targets
- Fall risks are identified prior to commencement of work
- Fall protection = to the risk is installed and used when working at site
- Personnel using Scaffolds, Elevated work platforms, fall restrain, fall arrest or self rescuing systems are trained and
competent
- Ladders are used in accordance with these safe work instructions
General
Falls can occur from ladders, roofs, scaffold or mobile platforms, when climbing stairs, or from incorrectly erected equipment.
The following situations are particularly hazardous:
- Work near unprotected open edges of floors or roofs
- Work near unguarded holes, penetrations and voids
- Work near unguarded excavations, trenches, shafts, lift wells
- Work from unstable structures (for example, incomplete scaffolding)
- Work on, or near fragile, brittle surfaces (for example, cement sheet roofs, fibreglass roofs, skylight)
- Work from unprotected formwork decks
- Work from unsecured ladders
Generally, fall protection must be provided for anyone who could fall 2 metres or more. However, if the type of work makes it
difficult to be fully aware of the location of the platform edge (for example, welding, Oxy acetylene cutting and other work
involving restricted vision) fall protection should be provided regardless of height.
Remember that a fall from any height can cause serious injury or death. Stay alert, even when working off
stepladders.
For your own safety remember the following points:
- You are not expected to work in any situation where there is a risk of falling
- Taking risks will not be rewarded
- Report any fall hazards you see on site.
- Do not use fall arrest equipment unless you have been properly trained in its use
- Don’t be afraid to offer solutions to fall hazard problems – your opinions are important and valuable
- Never work at heights next to an exposed edge without some form of fall protection
Pre Start Site inspection
Where work is to be conducted for another contractor.
Normal it is the responsibility of the principal contractor to provide access in the form of scaffolds for work on roofs, if no
access is provided discuss with the manager and or organise for access to be provided
Before work commences, (either during estimation, quotation phases or before the job commences) a review of fall
hazards must be undertaken. Inspect the site or area and look for Slippery surfaces, structural integrity, voids, weather
conditions etc.
Where the work involves the possibility of a fall employees should assess the best method of fall prevention.
The Selection of fall prevention methods should consider the:
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Safe Work Instructions Manual
- Consequence of the fall
- The duration of the work
- Industry good practice.
Hierarchy of Control Measures
Action
Suitability
Examples
Elimination
Excellent
Do the task at ground level or on a fixed work
platform of solid construction
Passive fall prevention devices
Good
The use of guard rails, safety mesh, elevated or
temporary work platforms (e.g. scaffold)
Work Positioning Systems
Reasonable Industrial rope access systems and travel restraint
systems
Fall Injury Prevention Systems
Acceptable
The use of fall arrest/control systems
Administrative Controls
Tolerable
Includes ladders (fixed and portable) and the use of
safe work procedures, instruction and supervision
and signs
The following rules apply to work at height.
Use of Scaffolds
- Scaffolding of more than 4 metres in height must only be erected and dismantled by a certified scaffolder, or a trainee
under the direct supervision of a person with a Certificate of Competency of the right class.
- Scaffolds should be used when the work to be conducted is high risk, the work involves a lengthy duration and /or the
need to perform work at height can not be eliminated
- Scaffolds will normally be the responsibility of the prime contractor but where they are the responsibly of the company
the supervisor or manager is responsible for ensuring their safe erection.
- Mobile scaffolding must not be used for access above 3 bays - use the scaffold with correct load rating for the
personnel and gear
- Light Duty - 225Kg per bay, Medium Duty - 450Kg per bay, Heavy Duty - 675Kg per bay
- Only Work Safe certificated scaffolders may erect, modify or dismantle scaffolding from which a person may fall 4
meters or more. (Ensure the ticket is for the correct class of scaffold)
- Before working from a mobile scaffold lock the wheels.
Safe Work Instructions Manual
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- Never move mobile scaffolds while workers are on them.
- Inspect scaffolding before use and after high winds. Check the inspection tag to see that it is safely constructed.
Ensure scaffolds are
- Fully planked, have guard rails, mid rails and cross bracing,
- Tied to the structure, on sound base plates, fitted with access
- Level at all times
- Fully planked and fitted with guardrails, mid-rails and toe boards on the working deck wherever a person or material
could fall more than 1.8 metres
- Fitted with a safe, secure temporary stairway or ladder to access the working deck
- Scaffolding components must comply with NO GO ZONE REQUIREMENTS
Defective or incomplete scaffolding must not be used and should be sign posted “Scaffold
Incomplete/Do Not Use”
Mobile Scaffolds
- Follow the manufacturers/suppliers written instructions for correct erection, use and dismantling
- Mobile scaffolds should be used only on a hard, level surface
- The wheels of a mobile scaffold should be
locked against any possible movement before
using the scaffold, and should remain locked
when not in use
- Do not relocate a mobile scaffold unless all
items have been secured against falling
- No person should be on a mobile scaffold when
it is being moved
- All mobile scaffolds should have a safe, secure
means of access to the working platform
- Do not locate a mobile scaffold closer than 1
metre to any slab edge, penetration or other
step down, unless a positive means to prevent it
crossing that point, such as a fixed fence, rail or
raised edge, is in place
- When moving a mobile scaffold, stay well clear
of power lines
Never use scaffold guardrails to gain extra
height or to support equipment or loads.
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Safe Work Instructions Manual
Use of Mobile Access Equipment
Where Scaffolds are not considered practicable mobile equipment might be used. See SWI 11 Use of mobile plant
Guard Rails, Perimeter Guarding
Guardrails may be used to provide effective fall protection at:
- The perimeters of building or other structures
- The perimeters of skylights or other fragile roof materials
- Opening in floor or roof structures
Guard rail systems are used to provide protection of the perimeter of a work area and thereby prevent falls from roofs. They
are used when roof slopes are between 0 degrees to 45 degrees from horizontal.
Where roof slopes exceed 45 degrees, the slope is unsuitable to work on without a support system, such as a roof ladder or
scaffold platform, to prevent sliding.
The guard rail system must be constructed to withstand a force of 0.55kN (approximately equivalent to 55kg) applied at any
point of the guard rail system.
The top handrail must be not less than 900mm or more than 1100mm above the working surface. If access points are
required for equipment (eg. hoist) they should be adequately protected with gates, safety chains or any other means to
prevent a person falling. Where guard rail systems are intended to be used in conjunction with steel structures or tilt-up
construction, designers and builders should plan for the guard rail and fixings to be attached to the panels prior to the
structures being raised from the ground.
When roof slopes are between 0
degrees to 15 degrees from
horizontal A guard-rail system
should incorporate a top rail,
mid rail and fender (toe) board.
infill mesh panel should be used
where people are likely to be
working below the edge of the
roof
When roof slopes are between
15 degrees to 35 degrees A
guard-rail system should
Incorporate a top rail, mid rail,
bottom rail and fender (toe)
board. The bottom rail should
be fitted midway between the
mid rail and the roof.
When roof slopes are between 35
degrees to 45 degrees. A guard-rail
system should incorporate a top rail,
mid rail, bottom rail, fender (toe)
board and infill mesh panel to mid rail
height. The bottom rail should be
fitted midway between the mid rail
and the roof. The infill mesh panel
may assist to reduce injury to a
person sliding down the roof into the
railing and will minimise the possibility
of objects falling from the roof.
Guarding Trenches, Pits and Excavations
Where trenching works present a risk of people falling on the site, any such risk may be controlled by the provision of:
- Guard railing
A barrier, approximately 2 metres back, to prevent people approaching the trench (the height of the barrier should be
sufficient to prevent people unwillingly falling over the barrier)
Safe Work Instructions Manual
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Trestle scaffolds
- Are only suitable for tasks requiring a working platform at a height of less than 2 metres above the supporting surface
- Should be constructed on a hard, level surface, with a platform width not less than 450mm for light duty work and not
less than 900mm for medium and heavy duty work
- Trestles should be fully planked and never ‘piggybacked’ to gain extra height. Work only between the trestles
- Do not use trestle scaffold if the platform not horizontal
- Materials and equipment on the platform can cause trips, spills and falls
- Loads should not be placed unevenly along platform length or be concentrated beyond the trestle or putlog.
- Consider barricading and signposting the area.
Restraint and Fall Arrest Systems
These are personal protective equipment (PPE), which should only be used when other means of providing
fall protection, such as scaffolds, guardrails and elevating work platforms have been considered and are not
practicable.
Before using an individual fall arrest system or travel restraint system you should be trained in its use.
Ensure the purpose-designed, temporary roof anchor is used in accordance with the manufacturer’s instructions - on
metal deck or tiled roofs.
Travel restraint systems should only be used for tasks of short duration where it is not practicable to adopt a fall protection
system that prevents falls
- Fall arrest and travel restraint systems require a Work Method Statement prior to use
- Prior to use, a fall rescue plan should be developed.
- Workers using fall arrest systems should not work alone
- Full body safety harness should be worn, not waist belts
- Lanyard and inertia reels should be attached to the rear shoulder attachment point of the harness
- Lanyard systems should be installed so that the maximum distance a person equipped with a harness would free fall
before the fall arrest system takes effect is 2 metres
- Energy or shock absorbers should be used with all lanyard, harness and inertia reel systems
- Do not directly attach a lanyard snaphook to an anchorage point, i.e. a ring. Use a karabiner passed through the eye of
the lanyard thimble to make the connection
- Avoid using inertia reels in a horizontal configuration where, in the event of a fall, the line can be snagged on sharp
edges
- Beware of using an inertia reel when working on a steep pitched roof. In a fall down the inclined surface of a steep
pitched roof the inertia reel line may not lock up
- An arrest line may fail if it contacts an edge in a fall. Ensure that verification has been obtained from the manufacturer
or supplier that it is safe to use with the specific type of edges involved in the work process
- Inertia reels should not be used as working supports by locking the system and allowing it to support the user during
normal work
- In order to avoid rollout, make sure you use the fall-arrest manufacturer’s recommended hardware such as energy
absorbers, karabiners etc
- Seek advice when you set up an inertia reel – avoid the pendulum effect
- Only a qualified rigger or scaffolder or other suitably trained person should install a static line system
Safe Work Instructions Manual
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- Suitably competent persons should undertake inspection of fall arrest systems
A restraint system is used to hold a person
back from and edge and getting into a fall
situation. A maximum distance of any limited
free fall must not exceed 600 mm. Restraint
system are commonly used on pole work to
enable free use of hands while on a ladder.
Other Equipment Systems
Other systems can also satisfy the classification of work positioning system. These systems include equipment, other
than temporary work platforms, that enable a person to be positioned and safely supported at a work location for the
duration of the task being undertaken at height. This may include the use of temporary static lines and roof workers’ kits.
Industrial safety nets
Safety nets can provide a satisfactory means of protection while allowing workers maximum freedom of movement. An
internal safety net may be an effective method of arresting falls for Class 10 buildings such as, machinery sheds or
garages. They can also be effectively used over stairwell openings. Heavy duty trestle scaffolds can be used as simple
and inexpensive catch platforms, particularly in voids and stairwells. Guidance on the use of safety nets is provided in
Work Safe’s Code of Practice for the Prevention of Falls in General Construction.
Catch platforms
A catch platform is a temporary platform located below a work area to catch a worker in the event of a fall. The
platform should be designed to sustain the maximum potential impact load. Scaffolding components maybe used to
construct a mobile catch platform.
All catch platforms should:
- Incorporate a fully planked out deck
- Be positioned to maintain a minimum of 2 metres beyond all unprotected edges of the work area, except where
extended guard railing is fitted to the catch platform
- Be positioned as close as possible to the underside of the work area,
- In no case be greater than 1 metre below the work area.
Ladder or administrative system
- Ladders should only be used when no other form of access equipment is suitable (and the job duration - fall risk is low)
- Ensure portable rung ladders are positioned at a 1 out to 4 up ratio (no more than 75 and less than 60 degrees from
the vertical)
- Ladders should be industrial grade (made of non conductive material – when working around electricity) and have non
slip feet
- Use 3 point contact when accessing ladders
- Secure ladders in use at the top and bottom
- When a ladder is being used as access it should extend at least 1 meter above the platform or landing
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The top cap and two top treads on a step ladder should not be used
- where it is possible for the ladder or user to come into contact with electrical power lines; in particular, metal or metal
reinforced ladders should not be used in the vicinity of live electrical equipment; such ladders should be permanently
marked with “do not use where electrical hazards exist
Ladders should not be used:
- in access areas, walkways, traffic ways or within the arc of swinging doors
- where the work involves restricted vision or hot work (e.g. welding)
- on scaffolds or elevating work platforms to gain extra height
- in very windy or wet conditions
- near an exposed edge or a guardrail where, if the ladder toppled, a person could fall over that edge
FALLING OBJECTS
Falling objects can injure or kill and are a hazard when overhead work is carried out.
Where protective platforms and screens cannot guarantee that falling objects will not present a threat, the
following safety measures should apply:
- A NO ACCESS area should be established below overhead work
- The NO ACCESS area should have secure barriers in place and adequate signage to prevent access into the area
- All employees should be made aware of the NO ACCESS area
- In certain circumstances a spotter may be necessary
Remember that there may be a danger to you from other trades working overhead and that your work may be
a danger to those working below.
Avoid being injured or injuring others by making sure that you:
- Always wear your hard hat in work areas
- Stay away from ‘No Access’ areas
- Keep away from loads being lifted and slung loads
- Secure loose material you use such as ply wood, iron-sheets and off-cuts against the wind
- Do not stack materials close to un-meshed guardrails and perimeter edges
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SWI 7 Manual Handling
Objectives and Targets
- Manual Handling risks are identified prior to commencing work
- Mechanical methods of moving materials are used wherever possible
- Repetitive jobs are rotated with non repetitive work
General
Factors that can contribute to increasing the risk of injury include:
- Repetitive or sustained application of forces
- Repetitive or sustained awkward postures
- Repetitive or sustained movements application of high forces
- Exposure to sustained vibration
- Handling of loads that are unstable, unbalanced or difficult to move
- Weight of objects (if carried or held)
- Bending the neck or back repetitively or for extended periods of time
- Jarring movements (using a sledge hammer to break concrete)
- Awkward movements such as twisting, bending or over-reaching, especially while carrying or manipulating a load
- Environmental conditions
- Personal factors such as age, physical capability or any disability or previous injury
Do Not:
- Work with your hands or arms above your head for extended periods
- Bend, lift and twist
- Use tools that vibrate for extended periods without breaks
- Move excessively heavy materials by hand – without mechanical or extra assistance
- Squat, kneel or work in awkward postures for extended periods
- Side load the body - distribute the weight evenly
Do:
- Keep a high standard of house keeping
- Assess the risks and plan the task before you commence work
- Use suitable mechanical aids
- Alternate repetitive tasks with other tasks or rest breaks
- Use two people to carry heavy or larger loads - push loads rather than pull
- Re-arrange work layout to reduce the need to bend, twist and over-reach
- Keep your body as close to the work as possible to avoid over-reaching
Safe Work Instructions Manual
- Lighten loads (as above)
- If you have to lift, remember:
o
Warm up before starting work or commencing a manual handling task
o
Keep the back straight and BEND THE KNEES
Page 40
Safe Work Instructions Manual
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SWI 8 Using Hand and Power Tools and Pressurised Equipment
Objectives and Targets
- All tools are inspected before use
- All faulty tools are withdrawn from service until they can be repaired or replaced
- Only trained and competent personnel are to use tools
General
When using hand tools a person may be stabbed, crushed, cut, caught, stuck by flying objects, be exposed to electricity,
pressures –(oil, gas, water), or be stuck by hand tools falling from above.
Do
- Inspect tools before use and maintain them adequately
- Secure the couplings between the air hoses and tools, using chains, wires or locks.
- Fit a safety device so that the air supply shuts off if the line breaks or the nozzle drops.
- Use appropriate PPE
- Never used compressed air to blow down clothing
- Only persons trained in the use of explosive powered tools may operate them
- Never use explosive powered or compressed air staple guns while other workers are in the line of fire or in range of
possible fire / misfire. Place warning signs (you must be authorised to use explosive powered tools)
- Check all grinding / cutting wheels for cracks, excessive wear, correct type / speed for machine, weathering
- Only use demolition saws with guards
- Only use demolition saws in well-ventilated areas
- Where excessive vibration occurs - use frequent breaks or alternate tasks to reduce vibration exposure times.
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SWI 9 Using or Contact with Hazardous Substances
Objectives and Targets
- Product MSDS are available on site for all Chemicals used at site
- Correct PPE is worn for the Chemical
- Chemicals are stored and disposed of in accordance with the MSDS requirements
What are Hazardous Substances?
Hazardous substances may be found in the materials used or processed at work.
They may be present on Sites in the form of Liquids, Solids, Gases, Fumes or Mists. Some Examples include
- paints, solvents, glues, sealants
- particle fibreboard, MDF, insulation material
- concrete, cements, cement finishes. concrete, bricks and some crushed rock such as granite, mortar (when dry cutting,
chasing, grinding etc
- grease, oils, fuels
- asbestos
- wood dust
- herbicides
Where there is any doubt as to the safety of a substance, expert advice should be sought.
Do:
- Remove all unnecessary hazardous substances from site
- Always obtain the MSDS for chemicals of hazardous substances used on site. Always read any warning label and
make yourself familiar with the site risk assessment and any safe operational procedures including all safety and
storage precautions
- Containers of hazardous substances must be adequately labelled
- If you are a contractor, make sure you bring a copy of the MSDS for the material you are using to the site and inform
the site manager
- Limit contact with hazardous solids, liquids, gases, fumes, mists, dusts, etc. through changes in work processes and,
where necessary, the use of effective PPE (e.g. gloves, respirators, safety glasses)
- Only perform hazardous dust, fume, mist, gas, liquid -producing processes in well-ventilated areas
- Always wear the correct PPE (respirators, gloves, face, eye protection, etc.) for the type of material / tool being used
- Store hazardous substances in accordance with the Manufacturers Instructions
- Take care not to spill hazardous liquids and clean up any spills immediately and safely in accordance with the warning
label and MSDS
- Do not work with asbestos-containing material. If you suspect such a material, see the Site Manager
- Never dry sweep hazardous dusts or debris that may contain them. Wet down materials that produce hazardous dusts
- Maintain all tools and equipment which have internal combustion engines so that exhaust emissions are kept to a
minimum
- Minimise the use of petrol, diesel, or gas powered equipment in restricted and poorly ventilated areas
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Silica & You
Silica dust can cause long term health effects such as silicosis, fibrosis (thickening and stiffening of the lungs) or lung
cancer when excessive amounts are inhaled.
Long-term exposure to silica bearing dusts increases the risk of ill health. Smoking also increases this risk.
Precautions to be observed when in contact with Silica
- Wash and / or wet down areas and clean up
- Keep windows on air-conditioned mobile equipment cabs closed
- Wear all Respiratory Protection Equipment with the correct particulate filter
- Clean up any dust spills.
Asbestos
If you identify or suspect materials as containing asbestos - contact the Manager- No employee shall remove or work on
asbestos containing materials without authorisation and training.
Mineral Fibres (eg insulated bats)
All employees are required to use gloves, disposable overalls and a P2 paper respirator (minimum) or half face respirator
with a P2 cartridge when handling or working in areas with Mineral Fibres
Medium Density Fibreboard (MDF) and Wood Products
MDF (medium density fibreboard), particle boards and some timbers such as western red cedar, birch, oak, walnut,
and others release wood dust when cut which may cause cancer and/or respiratory illness, MDF and other particle
boards may also release toxic chemicals.
These toxic chemicals include Formaldehyde, which is the bonding agent for MDF. When MDF is cut, the cut edges
release the gas into the environment.
Health Effects
EYES: The dust, gas and vapour may be irritating to the eyes causing discomfort and redness.
SKIN: The dust, gas and vapour may irritate the skin, resulting in itching and a red rash.
INHALED: The dust, gas and vapour may irritate the nose, throat and lungs, especially in people with upper
respiratory tract or chest complaints such as asthma.
CHRONIC: Repeated exposure over many years to uncontrolled wood dusts increases the risk of nasal cancer.
Inhalation of wood dusts may also increase the risk of lung fibrosis (scarring).
- There are also increased risks of respiratory and skin sensitisation from wood dust and formaldehyde resulting in
asthma and dermatitis respectively.
Do
- minimise creation and spread of dust
- use a fully enclosed restricted area if cutting where necessary
- use hand tools in preference to power tools or tools fitted with dust extraction
- use a half face protective cartridge respirator masks
- remove dust using an appropriate vacuum cleaner
- decontaminate work clothing and personal hygiene
Prior to work with any of these products, make sure that you obtain and read the MSDS for the product.
Always store MDF and other particle boards in a well-ventilated area.
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SWI 10 Danger Tag and Lock out Systems
Objectives and Targets
- Equipment that may become energised during maintenance or cleaning is isolated and tagged before work
commences
General
Lock out and tagging systems are used to prevent equipment from being inadvertently operated during cleaning,
maintenance, installation or commissioning.
Lock out and tag out systems are also used to prevent people from operating or using unsafe or out of service equipment.
Isolating, positioning of a lock out and placing a Danger Tag
Where work is to be carried out on a system, machine or circuit that has an energy source that may cause injury to
personnel, or under a “permit to work system” the following should apply:
1.
All potential energy sources that may impact on the work to be undertaken should be identified by a competent
person (eg, a qualified mechanic for mechanical isolations, electrician for electrical isolations etc)
2.
All identified isolation “Control Points” must be locked, pinned, closed or otherwise secured and a DANGER DO
NOT OPERATE tag and lock affixed to each point of isolation
3.
The Mechanic, electrician or other competent person shall:
o
Complete the isolation
o
Fit a lock, multi hasp and a DO NOT OPERATE TAG. Record their name, date and work to be completed on
the tag
o
Test integrity of isolation by turning the valve, or electrically testing
o
Once work is completed, the person placing the tag must check to see that the job is safe before removing their
tag.
NEVER REMOVE OR INTERFEER WITH ANY ONE ELSES TAG OR LOCK
Out of Service Tags
Out of service tags are only used when personnel are not in danger of injury. These may be used on equipment that is
overdue for servicing, waiting on parts, or otherwise unsuitable for general usage. They may also be used for
commissioning or re- commissioning activities.
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SWI 11 Use of Mobile Plant
Objectives and Targets
- Only trained / competent or licensed personnel operate Mobile Plant
- Plant is inspected and all log books are completed prior to use
- A work method statement is created for each work activity involving the use of Mobile plant
- Mobile plant is maintained by qualified personnel in accordance with the manufacturers instructions
General
Improper operation of mobile equipment can result in:
- Rollover
- Collision
- Striking personnel or vehicles
- Contact with electricity
Personnel, other contractors and the public can also:
- Slip and fall while mounting and dismounting
- Be exposed to manual handling injuries, noise, etc
Pre start Inspection
Before using hired or owned plant on any site, inspect the equipment and complete the log book - this will be reviewed by
the supervisor.
Review the job site. If the risks associated with work are not covered by an existing Work Method Statement, Risk
Assessment or if you consider them high, PREPARE A WMS BEFORE COMENCING WORK
General Rules
- Ladders or steps for mounting and dismounting equipment should be clean and maintained - Always use 3 point
contact when entering or leaving a machine
- Manufacturers maximum load limits and speed limits must not be exceeded
- Use ergonomically designed seating
- Take breaks from the task if excessive vibration is present.
- Equipment should not be used for purposed other than those specified by the manufacturer.
- If machinery is used for lifting this must only be done using approved lifting attachments and personnel should be
excluded from the area.
- Obey all electrical exclusion zones and precautionary measures (see SWI 3 Assets)
- All personnel working in, on or around should wear HI Visibility Vests
- Keep all working platforms clear of materials and tools
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- Use a harness in EWPs (where necessary)
- Do not approach any mobile equipment without visual contact with the operator
- Seat belts must be worn where they are fitted on mobile equipment
- Do not approach hydraulic hammers / drills when in operation - flying rock can cause sever injuries
- Travel in the bucket or on the outside of loaders and other equipment is prohibited
Licensing- Certification
Do not use the equipment if you do not have the clearance from your supervisor or are licensed for the equipment
Inspection / Routine Maintenance
- All defects should be reported to the Supervisor in writing
- All machinery should have an effective braking systems and all safety and warning devices such as reversing beepers,
motion detectors or lights should be fitted and operational
- Rollover protective structures (ROPS) or fall-over protective structures (FOPS) must be fitted to all heavy mobile
equipment - where there is a risk of rollover. All tractors over 1250Kg must be fitted with ROPS
Cherry Pickers
Platforms rotating at ground level need to have an unimpeded radius in which to rotate. This area may need to be
barricaded and/or signposted. The unit can only be placed on a hard, level surface unless it is specifically designed for
rough terrain. Mechanical failure can only be avoided with a thorough pre-operational inspection, including condition of the
tyres, ensuring guardrails are secure, no hydraulic fluid leaks, etc.
Hazards and Risks:
- If the WWL is exceeded or loads go beyond the confines of the bucket, it could result in the unit tipping over
- Consider the effects of strong winds on the bucket and boom
- Check for live powerlines and hidden underground cavities
- Competency: Persons operating boom-type EWPs with a boom length of 11 metres or more must hold, or be directly
supervised by, the holder of a certificate of competency.
Additional Precautions:
- Personnel must wear a full body harness and fall arrest device, as it is possible for the bucket to invert.
- Wheels are to be locked when the unit is stationary.
- Outriggers are usually deployed as a means of stabilizing plant.
- When using a self-propelled unit, travel with the boom in line with the direction of travel.
- Unless specified by the manufacturer, a boom has to be lowered before the unit travels.
Scissor Lifts
There must be no obstacles to impede elevation. The size of the working platform mirrors that of the base, where
stabilisers are deployed.
Rules and Principles:
- Scissor lifts are only to be used on firm, level surfaces
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- The top guard rail should not be breached by any person, hence a scissor lift should not be used, for example, to gain
access to a roof
- A pre-operational inspection is paramount as the concertina consists of a series of moving and hydraulic parts
Hazards and Risks: With a platform broader than that of a cherry picker, personnel need to resist the temptation to utilise
available space and carry more than the SWL. Do not use a scissor lift as a prop or a crane. Consider live overhead
powerlines and strong winds. Unlike a cherry picker, scissor lifts cannot be moved across once the lift is raised; don’t cut
corners by overreaching.
Competency: A certificate of competency is not required to operate a scissor lift however persons operating them should
be trained and competent in their use.
Additional Precautions: Operators are not required to use fall arrest systems as it is not possible for the platform to invert.
Some units are fitted with audible and/or visible alarms.
Forklift truck work platforms
Personnel must not be raised or carried on forklift tynes. Work platforms should only be used on forklift trucks that are
designed for their use.
Rules and Principles: Mechanical failure can only be avoided with a thorough pre-operational inspection, including
condition of the tyres and brakes, ensuring guardrails are secure, no hydraulic fluid leaks, etc. These units can only be
used on surfaces that are level.
Hazards and Risks: Overhead obstructions such as roof rafters or beams. Close proximity to moving parts of the mast
requires a guard to be in place. This and other aspects contribute to reduced visible contact between the driver and the
worker. The tynes on a forklift are designed to tilt away, meaning the platform could move. Operation must be smooth and
accurate.
Competency: The forklift operator must hold the appropriate certificate of competency.
Additional Precautions: Personnel must wear a full body harness and fall arrest device as the platform can shudder or tilt.
Guard rails should be in place where practicable. Clear communication methods should be established prior to use.
Safe Work Instructions Manual
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SWI 12 Hot Work (Welding, Braising, Cutting)
Objectives and Targets
- Hot work is carried out in accordance with AS 1674.1 – 1990Safety in welding and allied processes Part 1: Fire
precautions
- Only trained / competent personnel conduct cutting/ welding operations
- PPE is used
- Fire appliances are located in the area when hot work is carried out
- Exclusion areas are established around hot work areas
- Cylinders are secured in an upright position protected against mechanical damage
- Hot work in hazardous areas is carried out in accordance with procedures
General
Welding produces three types of radiation.
o
Visible – this can cause damage to eyes
o
Ultra-violet – this can burn the skin and cause “welder’s arc eye” or eye flash
o
Infra –red – this can burn the skin and eyes and cause changes in skin pigmentation and cataracts
Welding fumes can also cause nausea, and hot objects can cause burns or be ignition sources
Before use all equipment should be visually checked daily. Any equipment found to be damaged or suspected to be
leaking should be immediately removed from the work area to a well-ventilated space and an “Unsafe – Do Not Operate”
tag should be attached to the equipment, until it is repaired or removed from the site.
*Note: Too much oxygen is also dangerous. Do not store cylinders in lunchrooms. Use designated storage areas
Responsible person
All hot work (such as welding, soldering, cutting, grinding and similar) is only to be carried out by competent and qualified
personnel.
A responsible person is responsible for the safe execution of hot work (see work in hazardous areas)
Site set-up
Before hot work is commenced in any area, it shall be ensured that
o
The site is inspected and made safe
o
Any work that needs to be conducted adjacent to or above timber or rope, the timber shall be protected by
wetting or other suitable means from direct heat, sparks, slag and hot metal particles.
o
Arrangements are made to prevent any work off-cuts, hot metal, slag or electrode stubs lodging in places where
there is a possibility of starting a fire
o
When conducting hot work outdoors near dry grass or bush, the immediate area shall be cleared or wetted
sufficiently to prevent starting a grass or bushfire.
o
Equipment is fit for purpose and in good working order
o
Equipment is located so that if a malfunction of equipment occurs, a fire or explosion hazard is not created
o
o
Welding equipment should be located at a safe distance from the equipment being welded in a known
gas-free area.
o
Welding return leads should be connected as close as practicable to the point where the welding is being
done.
Shields or barriers are to be placed around welding jobs to prevent visual contact with welding arc.
Safe Work Instructions Manual
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o
Protective guards shall be stable, of ample size and arranged to prevent sparks, slag or hot metal
particles rolling beneath them or penetrating openings in them. Protective guards shall be made of fire
resistant material.
o
When shielding is required – non-combustible welding drapes should be used – dry canvas or rubberised
tarpaulins should not be used.
o
“Danger-Welding in Progress” signs are to be placed near the work area.
o
Ensure personnel work a safe distance away from welding or cutting.
o
Work areas are to be cleared of rubbish, debris and flammable material and are to be well ventilated.
o
Fume extracting systems should be used in poorly ventilated areas.
o
Welding should not be performed from ladders.
First aid and fire protection
Serviceable onsite fire fighting equipment must be so located and ready to operate should an emergency develop during
hot work. These shall be available within 10m of the work area and be appropriate to the type of fire hazard (preferably
attached to each welding and oxyacetylene kit)
A first aid kit shall be available in the welding area
Welders and any other person associated with the hot work shall watch for any fire that may occur, shall know where the
fire equipment is located, shall take immediate steps to extinguish any fire and know how to contact the nearest fire
brigade.
PPE
Wear appropriate PPE in accordance with SWI 1 PPE.
These include
o
Fire resistant gauntlet gloves to cover wrists and forearms
o
Safety boots
o
Overall or leather apron
o
Welding helmet and visor
o
Goggles
Double eye protection and hearing protection are required during grinding and buffing (goggles/safety glasses
plus welding helmet/full face shield).
Persons assisting the welding process are to be suitably clothed, use suitable eye protection and avoid
looking directly at the arc
SWMS
A WMS should be developed for all welding and hot work tasks.
The risk assessment should include provisions for:
- The work to be done under a hot work permit system
- Controls of risks from fire and explosions
- Electrical precautions when using arc welders
- Adequate ventilation of the work area
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Work in Hazardous areas
A hazardous area is defined as an area in which flammable liquids, vapours or gases, combustible liquids, dusts, fibres, or
other flammable or explosive substances may be present.
All hot work in a hazardous area will be undertaken under the authorization of a responsible officer. A responsible officer
is appointed to be responsible for the safe execution of the hot work and have the authority to enforce the requirements of
the legislation and standards with respect to employees, contractors and other workers.
Prior to performing hot work in a hazardous area;
o
Identify and control any fire hazard (including flammable or combustible liquids, gases, vapours, dusts, fibres or
substances) within 15m from hot work, including hazards above or below the work zone.
o
Isolate area from unessential personnel and vehicular traffic
o
Ensure proper ventilation and safe atmospheres.
o
Where natural ventilation is inadequate, use forced or induced draft ventilation
o
Ensure equipment, piping and tanks are thoroughly drained, flushed with water, dried, steamed and air
purged as necessary to gain an atmosphere that can be tested and certified as gas free.
o
Remove sludge and scale that may have entrapped volatile material
o
Tanks and lines adjacent to hot work should be properly vented to a safe area.
o
Pump, line and vessel bleeders, sample points, etc which could be a source of leakage should be
plugged off. All other potential sources of leaks should be identified and counter measured
o
Ensure safe entry and exit from the hot work area
o
All combustible material that cannot be removed should be covered and the covering safely secured.
o
Contaminated ground. Any ground contamination (e.g. oil surfaces and oil spills) should be cleaned and sanded
over (depth of 50mm) to prevent sparks or other hot material igniting vapour
o
A HOT WORK PERMIT must be issued. (see below)
Hot work permit
Before hazardous hot work commences, hot work in an operating facility or any at any other time deemed
necessary, the responsible person shall make a thorough inspection of the area and when satisfied that the
hot work may safely proceed shall issue a hot work permit.
When working under a client’s responsible person, their hot work permit procedure shall be followed.
Commencement and conducting hot work
Hot work shall only commence when the responsible officer is satisfied that the requirements of the
authorization and hot work permit have been complied with.
Hot work shall only be carried out during the period stated in the authorization/hot work permit.
Welders shall not work alone in hazardous hot work situations and shall be provided the assistance
considered as necessary by the responsible person.
All persons associated with the hot work shall be aware and understand the precautions and specifications
listed on the hot work permit and the safety requirements of the site.
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Oxyacetylene or LP Gas Brazing and Cutting
Equipment Preparation
 All welding cables, hoses, valves and connections are to be inspected prior to use for defects.
 All defects are to be reported to the supervisor for repair or replacement.
 Hoses are to be used for one kind of gas only. Acetylene and oxygen hoses are not to be interchanged.
 Hose connections are to be made by clips or crimps.
 Flash Back Arresters are to be in place on the operator’s side of each regulator of gas cylinders and on
torches as a minimum.
 Regulated acetylene pressures are not to exceed 103Kpa.
 Hoses are to be purged separately and consecutively to remove all gas mixture before igniting.
 Regulators, valves and cylinder threads are to be kept clean. Don’t handle with dirty or oily hands, rags
or gloves. Keep valve sockets free of grit, dirt, grease or oil.
 Check for leaks regularly using soapy water not a naked flame.
 Gas cylinders to display current inspection mark in accordance with AS2030.
 Before welding, soldering or flame cutting any tank, pipe or container that has held flammable
substances, it must be drained, cleaned and thoroughly purged.
Oxyacetylene use
 Cylinders are to be used in the order in which they are received from the supplier.
 Spark lighters only are to be used for lighting torches.
 Gas cylinders, when in use, are to be placed in a suitable trolley for safety, security and ease of transport.
Acetylene and butane is only to be used, moved and stored in an upright position.
 Regularly check connections and check valves.
 Mark completed work “hot” with white chalk.
 Cylinders are to be turned off, valve caps replaced and hoses removed when not in use.
 Don’t leave lighted torches unattended or placed on the ground. Don’t place torches, even when
extinguished, on old drums.
Handling and Storage of Cylinders
 Gas cylinders are to be kept in a secure, dry, well-ventilated and cool location and away from sources of
heat and the direct rays of sun. Temperatures shall not exceed 54 C.
 Cylinders are to be chained or otherwise secured in an upright position.
 Smoking is prohibited near gas storage areas. Cylinder storage areas should be well ventilated with ‘No
Smoking’ or ‘No Naked Flame’ signs displayed
 Cylinders are not to be stored within 3 metres of near combustibles, flammable materials, oil, grease etc.
 Separate Oxygen cylinders and LPG cylinders by 3 metres per AS 1596
 Oxygen and Acetylene cylinders may be stored together if less than 10 no. G sized Acetylene bottles are
stored at site. (See Note below)
 Empty cylinders are to be tagged ‘empty’ and caps replaced. Empty and full cylinders are to be stored
separately.
 Cylinders are not to be lifted by the valves.
 Valves are to be fully closed before moving cylinders.
 Regulators and hoses are to be detached from cylinders before moving unless a trolley or special carrier
is used
 Cylinders are not to be dropped, thrown, dragged, used as rollers or as supports.
 Cylinders are not to be lifted or lowered unless in a suitable box or suitable lifting attachments are used.
 Manifolded cylinder packs stored in the same container are to be at least 5 metres apart.
 Warning signs to be displayed as appropriate (e.g. Flammable Goods – No Smoking; Hazchem signs).
NOTE: Minor Storage (as defined in AS 4332), clause 2.2


Less than 500 Litres in total (oxygen and acetylene)
Less than 500 Litres of Acetylene
If only Minor Storage quantities are stored then Oxygen (Class 2.2) & Acetylene (Class 2.2) cylinders do not have to be separated.
(One G sized acetylene bottle holds 50 Litres water capacity – AS 4332 refers to capacity as litres of water)
If Minor Storage quantities are exceeded then oxygen and acetylene cylinders are to be separated and segregated in accordance with
clause 4.5 of AS 4332.
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Arc Welding
Preparation
 The frame of all arc welding and cutting machines is to be grounded; ensure earth stake is installed into
ground
 Welding power source has valid (3 monthly) tag for insulation and earthing resistance.)
 Voltage Reduction Device (VRD) fitted to welding power source.
 Test VRD (power on) for correct function of indicator lights for MMAW and Gouging Operation:
[(Green – Open circuit voltage/ less than d.c. 35 V or a.c. 35 V and 25 V rms), (Green flashing to Red
– welding in operation)]. Note: VRD inoperative in wire feed mode as shown by no illumination of
indicator lights.
 Welding grounds and lugs are to be securely attached by cable lugs, clamps or bolts.
 Regularly examine welding cables for cuts and abrasions. Do not use damaged or faulty cables or
equipment.
 Regularly examine main power cable from power source to wire feeder. Do not use wire feeder with
damaged/ exposed conductors or faulty power cable.
 Do not splice welding cables.
 If cable extension connectors fitted, ensure fully tightened, no conductors exposed and fully insulated.
 All defects are to be reported to the Supervisor for repair or replacement.
 Protect gas cylinders from falling sparks.
 Provide forced ventilation whenever work is carried out in limited or a confined space.
 For engine drive welding machines, ensure engine exhaust fumes dispersed away from work area and
other workers.
 Remove metallic/ plastic/ paint surface protection from the heat affected zone to reduce fumes.
 If MMAW welding in locations that promote excessive, perspiration, humidity, moisture, wetness such as
the following:
Coffer dams;
Trenches;
Mines;
Rain;
Underwater;
Partially submerged areas;
Splash zones;
Vessels/ tanks/ conductive confined spaces exposed to the sun;
Using very high pre-heat temperatures;
0
Hot weather (ambient temperature above 32 C

An observer, capable of responding correctly in an emergency must be present to monitor the welder (or
welders if they can be observed at the same time).
Welding Process
 Keep all doors, covers and panels in place when operating the machine.
 Ensure that the engine protection push button pops out when the engine is switched off.
 Full length of cable is to be stretched out on the ground.
 Do not adjust the current control while welding is in progress.
 Switch off the current to the electrode holder and remove the electrode whenever it is set down and is not
actually in use.
 Spent electrode stubs are to be disposed of in suitable metal bins.
 Mark completed work “hot” with white chalk.
 Ensure body positioning does not complete a conductive path for the welding circuit.
 Do not touch electrode tip or tip of wire with damp/ wet clothing or hands.
 Do not consider MMAW electrode coating as electrical insulation.
 Maintain wherever possible dry condition for gloves, clothing and footwear.
 Connect work/ return cable to the workpiece as close as possible to weld location.
 Do not coil welding cables around the body
 During arc strike and welding only touch workpiece with dry insulated material (glove, wood, etc).
Safe Work Instructions Manual

Page 53
Kneeling pads/ insulated mat and no exposed steel capped boots when process/ location requires welder
to kneel on workpiece whilst welding.
Final inspection, clean up and disposal
After hot work has been completed, inspections shall be carried out to ensure no smouldering materials remain.
The site or work area should be secured overnight and at the expiry of the hot work permit period.
At the completion of the job, all equipment should be returned to its normal mode and fire fighting equipment
brought to the hot work site returned to its normal storage.
If a fire occurs
If a fire has occurred that was of sufficient size to require extinguishment by either portable or permanent fire
extinguishing equipment;
o
o
o
o
The following details must be reported to the responsible person immediately after
a) Location of fire
b) Magnitude and extent of fire
c) Identification of fire extinguishing equipment used.
Equipment which was used must be promptly serviced
Notify (as appropriate) the relevant Fire fighting authority of details of fire
Ensure a watch is maintained in the vicinity of the location of the fire until such time as re-ignition is
not possible
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SWI 13 Dealing with Accidents, Incidents and Emergencies
Site Emergency Contacts
- The Emergency Contact Information will be completed by the Site Manager (during site induction).
Reporting Incidents
- All accidents, near-miss incidents and environmental spills must be reported to prevent the possibility of the accident or
incident reoccurring and to ensure your Workers Compensation entitlements are protected.
Emergency Response - Your Role
- Familiarise yourself with:
- The Site Plan
- Locations of first-aid boxes and fire-fighting appliances
- Emergency evacuation points
- Emergency phone and communication numbers
- Any specific duties you have under the site’s Emergency Response Plan
Responding to a Medical Emergency
Follow all site instructions in case of emergency evacuation - do not leave a site without getting clearance from the person
designated in control of the site or emergency
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Safe Work Instructions Manual
Minor First Aid Injury
Start
Small job or
lone worker?
Yes
No
On larger jobs
On small or lone worker
jobs
Assess the injury
Notify the supervisor
Locate the
The Site First-Aider
Have your injury
assessed, and treated
If in doubt insist on the
opinion of a Medical
Practitioner or Paramedic
Record the details of the
injury and any first-aid
treatment on the First-Aid
Treatment Register.
Record any First-Aid
supplies used on the FirstAid Box content list so they
can be replaced
Finish
Contact your employer and
treat the injury
If in doubt, contact the
nearest Hospital casualty
department and seek the
opinion of a Medical
Practitioner or Para-medic
Follow your company's
emergency procedure
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Safe Work Instructions Manual
Serious Medical Treatment Injury
Start
Small job or
lone worker?
Yes
No
On small or lone worker
jobs
On larger jobs;
Assess the injury
Notify the supervisor
Locate the Site FirstAider
Have your injury
assessed and stabilised,
Contact the ambulance,
or transport the injured
party to hospital is safe
to do so
Assist the supervisor or
manager to complete the
incident report
The Manager must report the
incident to the principle
contractor and Work Safe
Finish
Contact the ambulance or
the nearest person to ask for
assistance
Follow the client’s
emergency procedure where
appropriate
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Page 57
Basic First Aid Provisions
This is not intended as a First Aid lesson and employees are strongly encouraged to undertake an accredited First Aid
course, however the following information may be helpful if you find yourself in this situation.
Control of Bleeding
- Apply direct pressure over wound using hands.
- Elevate or raise the limb.
- Apply a pad and a firm bandage – use clothing or rags if necessary.
- Remember to check circulations below the bandage. If any numbness, tingling or blueness occurs, loosen the
bandage.
- Seek medical or first aid assistance.
Eye Injuries
- Wash the eye(s) with eyewash or clean water.
- Do not attempt to remove any foreign material stuck in the eye – place a covering over the eye(s) (do not put pressure
on the eye) and seek medical assistance immediately.
Chemicals
- Wash or flush eye with cool, clean water for at least 15 minutes.
- Wash from the nose outwards and always wash under the upper eyelid.
- Seek medical attention.
Burn Injuries
- Cool the burnt area with cool water for at least 10 to 15 minutes.
- If necessary to prevent contamination, cover the area with clean dressing or plastic wrap.
- Seek medical attention.
- Never burst blisters.
- Never remove clothing that is stuck to a burn.
- Do not apply creams or ointments.
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Minor Wounds (abrasions and minor cuts)
- Clean the wound with mild antiseptic or soap and water.
- Cover lightly with a clean dressing.
- Seek first aid or medical attention.
Loss of Consciousness
Loss of consciousness can occur as a result of a number of different workplace accidents such as falls, slips and trips,
electrocutions, falling objects, oxygen deficient atmospheres and as a result of shock from traumatic injuries. If you
discover an apparently unconscious person, the following steps should be taken in the first instance.
EAR / CPR
Danger
- Check the risk of danger to yourself, the casualty and others. Has the person fallen? Are other people or objects likely
to fall? Is there an electrical hazard?
- Call out loudly “Help! Person down.” until help arrives.
- Call an ambulance
Response
- Check for response. Gently shake and shout. If no response, proceed carefully to next step.
Airways
- Check to see that the patient’s airways are not obstructed. If necessary, carefully turn the person on to the side and
remove any obstructing material.
Breathing
Is the casualty breathing? Look for movement, listen for breathing, and feel for their breath with your cheek. If the patient
is not breathing, proceed as follows:
- Tilt the head back and raise the chin forward
- Gently pinch the nose closed
- Seal your mouth over the patient’s mouth and blow
- Give five quick full breaths, followed by one breath every four seconds, until the patient breathes or help arrives.
Circulation
Does the patient have a Pulse? Check by placing your forefinger and middle finger (not thumb) on the patient’s wrist, or
neck. - Seek emergency medical help at once.
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Fire Explosion and Environment Emergencies
Fire
Typical fuels that may exist at work sites include:
- Vapours, gasses and fumes from materials and chemicals
- Gasses – e.g. oxy acetylene, LPG
- Timbers, paper etc
- Fuels and heat can be produced by chemical reactions and these can lead to spontaneous ignition.
You can assist in the prevention of fires and enhance workplace safety by taking the following general steps:
- Never use petrol, thinners, turps or other flammable substances near naked flames or hot surfaces.
- Ensure that areas where welding, grinding, cutting, burning-off or other hot work is carried out are free from
combustible materials.
- Obey all signs prohibiting smoking or naked lights. If you smoke, only do so in designated areas
- Use, handle and store volatile liquids and chemicals carefully, in accordance with material safety data sheet
instructions
- Use, handle and store oxyacetylene, LPG equipment with care and have a fire extinguisher present at all times.
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Safe Work Instructions Manual
When Fires or unplanned Explosions Occur
Fires or unwanted explosions can occur at any time. If a fire or explosion emergency occurs, follow the procedure below.
Start
Explosion occurs/
Fire observed
Can the fire
be
extinguished
safely?
Yes
Extinguish and
report it to the
Supervisor/
client Manager
immediately
No
Warn others in the local
area
Stop machinery if safe to
do so
Notify Client and Co
Supervisor/ Manager
Client will assess or
make an assessment
General
Evacuation
Required?
No
Evacuate area to a
safe distance
Do not leave
evacuation point
until instructed to
do so
Finish
Yes
Follow client
Emergency
Response plan
and instructions (if
applicable)
Call Fire brigade/
Move to a safe
distance / Evac
Point
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Page 61
INDUCTION SIGN-OFF
Staff Member
I have completed induction procedures and training applicable to my appointment
and have complied with all requirements of my Offer of Appointment.
________________________________________________
Signature of Staff Member:
______ / _______ / __________
Date:
Supervisor
I certify that the above mentioned staff member has completed induction
procedures and received training in the attached Safe and Environmental Work
instructions.
________________________________________________
Signature of Supervisor or other delegated officer
______ / _______ / __________
Date:
Printed Name: _______________________________________________
Position: ____________________________________________________