Maintenance and workshop support risk assessment (NSW)
Isolation and lock-out, stored energy, compressed air, extraction system maintenance, electrical work, battery charging and LPG, housekeeping, hazardous waste, yard work, contractors and the office – 42 hazards already identified and rated.
Section I – Maintenance and Workshop Support. 10 activities, 42 hazards, 128 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 10 activities in this section
Every activity is assessed in three parts – General Safety (18 hazards), Fire and Explosion (10) and Occupational Hygiene (14). Untick any activity you do not carry out and it drops out of your assessment.
✓Access to the Section I 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
Unplanned maintenance and facility support activities often bypass standard operational safety checks, leading to severe incidents. This module secures your background operations, covering everything from complex machine maintenance to contractor management and yard work.
Maintenance kills people in otherwise well-run workshops, because it is the moment the guards come off. Unexpected start-up, stored hydraulic and pneumatic energy, live electrical parts and work at height on extraction ducting are the hazards behind most maintenance fatalities – and contractors, who do much of this work, know your site least.
This section covers the ten support activities that sit behind production: machine maintenance and tooling changes, compressed air systems, local exhaust ventilation maintenance and filter changes, forklift battery charging and LPG cylinder changes, electrical work on plant, housekeeping of metal dust, swarf and offcuts, hazardous waste handling, outdoor yard work, contractor work in the workshop, and design, drafting and office work.
It applies to any manufacturing workshop, and is the section most often bought alongside the production sections.
Section I – Maintenance and Workshop Support
Workplace risk assessment for a bolted steel tank manufacturing workshop in New South Wales, Section I: Maintenance and Workshop Support: 10 activities, 42 hazards and 128 controls covering lockout/tagout of heavy plant, working at heights, confined spaces, hot work and electrical hazards. 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.
- ✓42 hazards across 10 activities, each with its consequences and inherent risk already rated
- ✓128 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 I – Maintenance and Workshop Support. 10 activities, 42 hazards, 128 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 maintenance and workshop support
A sample of the 42 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.
Crush, amputation, fatality. General Safety · inherent risk 4C.
Crush injuries, fluid injection injuries. General Safety · inherent risk 4C.
Amputation, crush. General Safety · inherent risk 4C.
Falls causing fractures, head injury, permanent disability or death. General Safety · inherent risk 4C.
Workshop fire. Fire and Explosion · inherent risk 4C.
Asbestos-related diseases (mesothelioma, lung cancer, asbestosis). Occupational Hygiene · inherent risk 4B.
High short-term exposure to carcinogens and sensitisers. Occupational Hygiene · inherent risk 3D.
Increased exposure to fume and dust across the workshop. Occupational Hygiene · inherent risk 3C.
Fire. Fire and Explosion · inherent risk 3B.
How one hazard is rated
Hazard I1.1 – Unexpected start-up during maintenance – starts with an inherent risk of 4C, rated before any controls are counted. The calculator lists 4 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.
- ✓Any workshop that maintains its own machinery or changes its own tooling
- ✓Sites with compressed air receivers, extraction systems and dust collectors
- ✓Businesses that bring in contractors for electrical, hot work or building work
- ✓Older buildings where asbestos-containing materials may be disturbed
- ✓Owners who need an isolation and lock-out risk assessment and a contractor management check
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.