Every stage of tank manufacturing, risk assessed.
Nine risk assessments covering a bolted steel tank workshop from receiving steel to dispatch and maintenance. Answer Yes, No or N/A for each control online; get colour-coded residual risk, a prioritised Action Plan and a Word report to print and sign.
All nine sections, A to I. Each section is also sold on its own below.
Secure checkout via Stripe. Instant download of all 9 documents after payment.
What this pack is
A bolted steel tank workshop runs a long chain of different work – receiving steel, cutting and forming, welding, blasting and coating, liner fabrication, insulation, trial assembly, dispatch and maintenance – and each stage has its own hazards. This set covers the whole chain in nine risk assessments: 60 activities, 350 hazards and 1491 controls, written for New South Wales by an occupational health and safety professional, with the inherent risk of every hazard already rated.
Each section is completed in an online calculator. You walk the workshop and answer Yes, No or N/A for every control. The calculator works out a control score and a residual risk for each hazard, colour coded red, yellow or green against the risk matrix, builds a prioritised Action Plan from every control answered No, and produces one finished Word report – method, hazard register, results, Action Plan, checklist answers and signature blocks – to print and sign. Your answers are saved, so the annual review only changes what has changed.
The 9 documents, in detail
Every document is authored for NSW, supplied as an editable, unbranded Microsoft Word file, and ready to complete for your specific assets. No blind purchase — here is exactly what you receive.
Section A – Receiving, Storage and Materials Handling
6 activities, 56 hazards and 339 controls covering unloading coil and sheet steel, unpacking shipping containers, racking and storage, overhead crane lifting, forklift and telehandler operation, and storage of gases and chemicals. Online calculator, printable walkthrough checklist and Quick Start Guide.
Section B – Cutting and Forming
11 activities, 82 hazards and 361 controls covering decoiling, guillotine shearing, punching, drilling, plate rolling, press brake bending, roll forming, plasma and oxy-fuel cutting, sawing and hand grinding. Online calculator, printable walkthrough checklist and Quick Start Guide.
Section C – Welding and Fabrication
8 activities, 51 hazards and 215 controls covering welding of galvanised steel, stainless steel and aluminium, fabrication of ladders, platforms, nozzles and manways, pickling and passivation, and zinc-rich touch-up. Online calculator, printable walkthrough checklist and Quick Start Guide.
Section D – Surface Preparation and Coating
8 activities, 40 hazards and 152 controls covering abrasive blast cleaning, chemical pre-treatment, powder coating, curing ovens, wet epoxy and polyurethane coatings, spray booth cleaning and coating inspection. Online calculator, printable walkthrough checklist and Quick Start Guide.
Section E – Liner and Membrane Fabrication
6 activities, 27 hazards and 106 controls covering cutting liner membrane, hot-air, hot-wedge and extrusion welding, solvent bonding of PVC liners, seam testing and packing. Online calculator, printable walkthrough checklist and Quick Start Guide.
Section F – Insulation, Sealing and Accessories
4 activities, 15 hazards and 58 controls covering cutting and fitting PIR/PU panels or mineral wool, sealants, mastics and gaskets, accessory assembly and kitting. Online calculator, printable walkthrough checklist and Quick Start Guide.
Section G – Quality Assurance and Trial Assembly
4 activities, 20 hazards and 71 controls covering dimensional inspection and marking, weld inspection and NDT, hydrostatic and leak testing, and trial bolt-up of tank rings. Online calculator, printable walkthrough checklist and Quick Start Guide.
Section H – Dispatch
3 activities, 17 hazards and 61 controls covering crating, strapping and banding, loading trucks and containers, load restraint, and preparing oversize loads. Online calculator, printable walkthrough checklist and Quick Start Guide.
Section I – Maintenance and Workshop Support
10 activities, 42 hazards and 128 controls covering machine maintenance, compressed air, LEV maintenance, battery charging and LPG changes, electrical work, housekeeping, hazardous waste, yard work, contractors and office work. Online calculator, printable walkthrough checklist and Quick Start Guide.
✓Each section opens in its own online calculator, tied to the email address used at checkout. The Complete Master Bundle opens all nine.
✓Every section downloads as a finished Word report (.docx) you can print, sign and keep with your safety records.
✓A printable walkthrough checklist (.docx) for each section, for marking by hand on the workshop floor.
Bolted Steel Tank Manufacturing Risk Assessment – Complete Master Bundle (Sections A to I) – NSW, ready to use
All nine workplace risk assessments for a bolted steel tank manufacturing workshop in New South Wales, from receiving and storage through cutting, welding, coating, liners, insulation, quality assurance and dispatch to maintenance: 60 activities, 350 hazards and 1491 controls. Each section is completed in its own online calculator, which works out control scores, residual risk and a prioritised Action Plan and produces a finished Word report to print and sign. Includes a printable walkthrough checklist for every section and a Quick Start Guide.
- ✓All 9 documents, authored to NSW law
- ✓Editable, unbranded Microsoft Word (.docx)
- ✓Single-site licence · use across your ABN
- ✓Instant download after payment
- ✓12 months of regulatory updates included
All nine sections, A to I. Each section is also sold on its own below.
Secure checkout via Stripe. Instant download of all 9 documents after payment.
11 hazards, identified and controlled
These are the hazards the documents are built around — each with the consequence that makes it matter, rated by priority. This is the depth a regulator expects and a generic template does not carry.
Lung cancer, occupational asthma and metal fume fever from uncontrolled fume, especially on stainless steel.
Irreversible respiratory sensitisation; fire and explosion from solvent vapour.
Workers and truck drivers struck by forklifts and reversing vehicles in receiving and dispatch.
Amputation and crush injuries at unguarded or poorly isolated machinery.
Fatal crush injuries from dropped coils, sheet packs and tank rings.
Entanglement, electric shock and stored-energy release during servicing of plant.
Respirable dust and heavy metal exposure from blasting and surface preparation.
Falls from truck decks, trial-assembled tank rings and maintenance access.
Permanent hearing loss and vibration injury from cutting, grinding and forming.
Carcinogen exposure in receiving bays and acute poisoning when unpacking imported containers.
Back and shoulder injuries from sheets, strakes, liner rolls and fittings.
Where holding only a SWMS goes wrong
Hazard A1.1 – Mobile plant – trucks and forklifts in receiving bay – starts with an inherent risk of 4C (red). On the walkthrough, a workshop finds only two controls in place: physical barriers between pedestrian walkways and the unloading bay, and a designated unloading bay. The other ten – reversing alarms, zone lights, reversing cameras, licensed operators, a trained spotter, a traffic management plan and more – are missing. The control score is 18.8%. Too few effective controls are in place to lower the likelihood, so it stays at C; but the barriers physically limit how serious an injury could be, so severity drops from 4 to 3. The residual risk is 3C (yellow), and the ten missing controls go into the Action Plan in priority order, each needing a responsible person and a due date.
The control measures in every document
Not generic advice — the specific, hierarchy-of-controls measures written into the pack, matched to how these assets actually fail.
Built for the people who do this work
If you operate, maintain or contract to these assets in NSW, this pack is written for your duties.
- ✓Bolted steel, stainless and panel tank manufacturers in New South Wales
- ✓Steel fabrication and heavy engineering workshops with cutting, welding and coating on one site
- ✓WHS managers and coordinators who need a documented, workshop-wide risk assessment
- ✓Owners and directors who must show how risks were assessed and what is being done about them
- ✓Workshops preparing for a customer, insurer or regulator audit
Authored to the codes and the law
The Codes of Practice and Australian Standards these documents are measured against, and the legislation behind them.
- §Work Health and Safety Act 2011 (NSW)
- §Work Health and Safety Regulation 2025 (NSW)
- §SafeWork NSW Code of Practice: How to manage work health and safety risks
Frequently asked questions
The documented system, ready to complete.
9 NSW documents, instant download, editable and unbranded, yours to own — authored to the WHS Act 2011 (NSW) and WHS Regulation 2025 (NSW).
All prices AUD incl. GST · Instant download · Single-site licence · 12 months of updates
This pack is a documentation set to support due diligence — it is not compliance in itself. You must complete the documents for your specific assets, have trained and competent workers, hold calibrated equipment, drill any rescue plan on your actual assets, and — where exposure is uncertain — obtain personal exposure monitoring data from a competent person. See the full Disclaimer & Terms of Use within each downloaded document.