Liner and membrane fabrication risk assessment (NSW)
Hot-air, hot-wedge and extrusion welding of PVC, PP and PE, solvent bonding, seam testing and handling heavy liner rolls – 27 hazards already identified and rated. Answer Yes, No or N/A on the floor and download the finished Word report.
Section E – Liner and Membrane Fabrication. 6 activities, 27 hazards, 106 controls.
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The 6 activities in this section
Every activity is assessed in three parts – General Safety (11 hazards), Fire and Explosion (6) and Occupational Hygiene (10). Untick any activity you do not carry out and it drops out of your assessment.
✓Access to the Section E online calculator, tied to the email address used at checkout. Untick any activity you do not carry out and it drops out of your checklist, results and report.
✓A finished Word report (.docx) with every hazard, your answers, the residual risk and your Action Plan already in it – to print, sign and keep with your safety records.
✓The pre-written Inherent Risk Assessment (.docx): every hazard in this section with what could go wrong, the possible consequence and its inherent risk rating – your reference copy, to read before the walk and share with the people you consult.
✓A printable Word walkthrough checklist for marking by hand on the workshop floor, an illustrated Quick Start Guide (PDF) and a one-page calculator login sheet.
What this pack is
Liner fabrication looks low-risk next to the steel side of the workshop, and that is why it is usually left out of the risk assessment. It should not be: heated plastics give off irritant and toxic fume, solvent cements are highly flammable, liner material burns fiercely once alight, and rolls and folded liners are some of the heaviest and most awkward manual handling in the building.
This section covers unrolling, measuring and cutting membrane; hot-air and hot-wedge seam welding; extrusion welding of PP and PE fittings and boots; solvent bonding and adhesive patching of PVC liners; seam testing by air lance, vacuum box and spark test; and folding, packing and palletising.
It suits any business welding geomembrane, pond and tank liners or thermoplastic sheet.
Section E – Liner and Membrane Fabrication
Workplace risk assessment for a bolted steel tank manufacturing workshop in New South Wales, Section E: Liner and Membrane Fabrication: 6 activities, 27 hazards and 106 controls covering polymer off-gassing, heat sealing fume, solvent-based adhesives and manual handling. Completed in the 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 and a Quick Start Guide.
- ✓27 hazards across 6 activities, each with its consequences and inherent risk already rated
- ✓106 controls listed for you, ranked by the hierarchy of control – you answer Yes, No or N/A
- ✓Colour-coded residual risk and a prioritised Action Plan, worked out for you
- ✓A finished Word report to print and sign
- ✓The pre-written Inherent Risk Assessment in Word, a blank walkthrough checklist, an illustrated Quick Start Guide and a calculator login sheet
Section E – Liner and Membrane Fabrication. 6 activities, 27 hazards, 106 controls.
Secure checkout via Stripe. Sign in and start as soon as the payment goes through.
Need more than one section? See the complete workshop
The most serious hazards in liner and membrane fabrication
A sample of the 27 hazards in this section, each shown with its consequence and the inherent risk rating given by a Certified Industrial Hygienist before any controls are counted. The controls themselves are in the calculator.
Electric shock, fatality. General Safety · inherent risk 4B.
Rapid fire with toxic smoke (hydrogen chloride from PVC); major property damage. Fire and Explosion · inherent risk 4B.
Flash fire or explosion; serious burns; major property damage. Fire and Explosion · inherent risk 4B.
Eye and respiratory irritation; headache. Occupational Hygiene · inherent risk 3C.
Headache, dizziness, narcosis; liver effects with long-term exposure; eye irritation. Occupational Hygiene · inherent risk 3C.
Crush injuries to feet and legs; back injury. General Safety · inherent risk 3C.
Burns. General Safety · inherent risk 3C.
Eye injury; air injection into skin. General Safety · inherent risk 3C.
Low back, shoulder and hand injuries (musculoskeletal disorders – the most common serious workers' compensation claim type in Australia). Occupational Hygiene · inherent risk 2D.
How one hazard is rated
Hazard E2.2 – Electric shock from welders and leads – starts with an inherent risk of 4B, rated before any controls are counted. The calculator lists 3 controls for it, from elimination and engineering down to PPE, monitoring and emergency arrangements. You answer Yes, No or N/A for each on the floor. Once the last one is answered, the calculator works out the control score, applies any severity reduction earned by physical controls, and shows the residual risk as RED, YELLOW or GREEN. Every control you answered No to goes into your Action Plan, most urgent and most effective first, ready for a responsible person and a due date.
How your controls are scored
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.
- ✓Tank manufacturers that fabricate their own liners
- ✓Geomembrane, pond liner and dam liner fabricators
- ✓Workshops extrusion welding PP and PE fittings
- ✓Sites using solvent cements and adhesives on PVC
- ✓Businesses spark testing seams with high-voltage holiday detectors
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
Add an in-house CIH risk assessment review
Complete your risk assessment using our digital engine, then have our in-house Certified Industrial Hygienist (CIH) and Full Member of the Australian Institute of Occupational Hygienists (MAIOH) review your specific results to ensure bulletproof compliance.
Post-completion expert review
Not sure if you categorised your site’s controls correctly? Complete your online assessment and send us the generated report. Our in-house experts will review your residual risk scores, validate your “N/A” selections, and ensure your action plan adequately addresses your highest liabilities (like hexavalent chromium or LEL environments) before you sign off.
- Scope
- Remote CIH and MAIOH review of your completed calculator report and hazard register.
- Turnaround
- 3–5 business days.
- Pricing
- Remote review is billed at an hourly rate of $250 AUD/hour (total quote based on the number of sections reviewed).
Walk it, answer it, sign it.
The calculator generates a finalised, fully formatted .docx record with your Action Plan already inside it. Print it, sign it off, and you are audit-ready for this part of your workshop.
Price includes GST · Jurisdiction: New South Wales – WHS Act 2011, WHS Regulation 2025 and SafeWork NSW Codes of Practice applied
This is a generic risk assessment for a typical workshop, to support your due diligence – completing it is not compliance in itself. You must answer it for your own site, consult your workers, put the missing controls in place, and get competent advice where it says so – for example exposure monitoring by an occupational hygienist. The limits of the assessment are set out in “How it works” and at the front of every report.