Risk assessments written for your kind of workshop (NSW)
Not a blank template. Each industry is a complete hazard register with its starting risk ratings already set by a Certified Industrial Hygienist, and an online calculator that works out where you actually stand.
Twenty-three industries, each sold on its own below. The suite covers all of them.
Secure checkout via Stripe. Sign in and start as soon as the payment goes through.
Find your workshop
Each industry is a complete risk assessment in its own right, priced by the hazards it carries rather than its size. Buy the one that matches your work; the suite covers every industry for a group or a consultancy. One purchase gives permanent access to that industry’s calculator and report generator, plus the inherent hazard register and a printable walkthrough checklist.
✓Every industry is a separate product: buy the one that matches your workshop, or a suite covering a whole tier.
✓1292 hazards and 10,275 controls in total, each rated for severity and likelihood before you start.
✓Each one is completed in its own online calculator on a phone, tablet or computer, and answers save as you go.
✓A finished Word report per industry, with the residual ratings and a prioritised Action Plan already in it, to print and sign.
✓A printable walkthrough checklist and the inherent hazard register, for a clipboard on the workshop floor.
One assessment per kind of workshop
Welding and metal fabrication carry a heavier occupational hygiene burden than most workshop trades. Welding fume is classified as carcinogenic to humans, and what comes off the arc depends on what is being cut or joined: hexavalent chromium from stainless, zinc from galvanised steel, ozone from aluminium, manganese from mild steel wire.
Each industry here is a complete risk assessment for one kind of workshop, with the hazards and their starting ratings already identified by a Certified Industrial Hygienist. You answer Yes, No or N/A to the controls, and the calculator works out your residual risk, builds the Action Plan and produces the finished report.
- ✗You are left to identify every hazard yourself
- ✗You argue about the starting risk with no baseline
- ✗You work the hierarchy of controls out by hand
- ✗You spend hours formatting a Word document
A generic template leaves you with most of the work and all of the liability. Welding fume, hexavalent chromium and isocyanates are where the health claims come from, and they are the hazards a general template handles worst.
Every industry — the complete suite
Every fabrication and welding risk assessment in the library, for group safety managers, multi-site manufacturers and consultancies. 23 industries covering 1292 hazards and 10275 controls across safety, process safety and occupational hygiene. Each one 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.
- ✓All twenty-three industries, written to NSW law
- ✓Safety, process safety and occupational hygiene assessed separately in every one
- ✓Completed online on a phone, tablet or computer — answers save as you go
- ✓Colour-coded residual risk and a prioritised Action Plan, worked out for you
- ✓One finished Word report per industry, to print and sign
Twenty-three industries, each sold on its own below. The suite covers all of them.
Secure checkout via Stripe. Sign in and start as soon as the payment goes through.
CIH & MAIOH authored: the exposures that carry the liability
Standard safety checklists miss the chronic health exposures that trigger the biggest claims. These assessments are written by a Full Member of the Australian Institute of Occupational Hygienists, with control scoring for hexavalent chromium and welding fume, ozone at the arc, isocyanate coatings, respirable crystalline silica, purge gas asphyxiation and lead paint on old steel.
Every serious exposure in this workshop depends on what the coating contains. Zinc gives metal fume fever, old paint gives lead and the duties that come with lead process work, primers give hexavalent chromium, plating gives cadmium, and two-pack coatings give isocyanates. Without identification the business cannot select controls, cannot select respiratory protection, and cannot know which statutory duties have been triggered.
Lead damages the nervous system, kidneys and blood, and reduces fertility. It crosses the placenta. Where lead is present the work is lead process work under the WHS Regulation, which carries duties to notify SafeWork NSW, to provide blood lead monitoring, and to remove a worker from lead risk work at defined blood lead levels. Those duties apply whether or not the business knew the paint contained lead.
Stainless releases hexavalent chromium and nickel, galvanised releases zinc, coated pipe releases lead and chromate, and lined pipe releases the decomposition products of the lining. Pipe that has been in service may contain flammable or toxic residue. None of these are controlled by arrangements written for clean carbon steel.
Crush and amputation of fingers, hands and arms; a shell that rolls or springs can crush a person against plant or the wall. Rolling machines draw material in faster than a person can let go.
Amputation of fingers and hands, degloving, crush injuries. Press brakes and guillotines account for a large share of serious machinery amputations in Australian workshops.
Manganese neurotoxicity, which is irreversible; hexavalent chromium, a carcinogen with no exposure limit from 1 December 2026; nickel, a carcinogen and sensitiser; and cobalt, which causes occupational asthma and hard metal lung disease. A hardfacing run delivers several of these simultaneously at concentrations far above ordinary welding.
Explosion of a sealed vessel, drum or hidden gas cylinder; release of asbestos from lagging and linings; lead and chromate from coatings; refrigerant and PCB oil; and, rarely but seriously, dispersal of a radioactive source through the yard and into the furnace, which contaminates the site and everyone who handled it.
Crush and amputation from the machine; struck-by and crush from the grab and from dropped material; and ejected fragments travelling a considerable distance from the feed opening.
Falls from height are a leading cause of workplace death in Australia. A fall into water adds drowning, and a worker in leathers and boots with a helmet cannot self-rescue. Cold water and current reduce survival time sharply.
Silicosis, progressive and irreversible, including accelerated silicosis from high exposures over a few years; lung cancer; chronic obstructive pulmonary disease; autoimmune disease. Respirable crystalline silica is a Schedule 14 substance requiring health monitoring where there is a significant risk of exposure.
The highest single-task fume and noise exposure in the workshop. A short gouging run can deliver more manganese than a full shift of welding, and at 110 dB(A) the daily noise limit is reached in under two minutes. Because it is rework, it is routinely left out of exposure assessments.
Carbon monoxide causes headache, nausea, impaired judgement and unconsciousness, and it impairs judgement before the person notices anything is wrong. It has no smell or colour. In a small studio with one person working alone, collapse is not discovered until someone else arrives.
How one hazard is rated
Take a stainless steel shop welding a food-grade tank. Hexavalent chromium from the arc starts as a severity 5, probability C hazard, which is red. The shop has on-torch extraction and a respiratory programme with fit testing, but no booth and no air monitoring. The calculator scores the controls actually in place against the controls that apply, lowers the likelihood by the band that score reaches, and lowers the severity only because extraction at the source physically limits the exposure. The missing controls become the Action Plan, most urgent first.
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.
- ✓Fabrication and welding workshops in New South Wales
- ✓Owners and managers who need a risk assessment that stands up to a SafeWork NSW visit
- ✓Safety coordinators covering several workshops or several trades
- ✓Workshops whose insurer, principal contractor or client has asked for a documented assessment
- ✓Trainers and supervisors inducting apprentices onto workshop hazards
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)
- §Workplace exposure standards for airborne contaminants (Safe Work Australia)
- §AS 1674.1 and AS 1674.2 — Safety in welding and allied processes
- §AS/NZS 1715 and AS/NZS 1716 — Selection, use and maintenance of respiratory protective equipment
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 finished, fully formatted .docx record with your Action Plan already inside it. Print it, sign it off, and you are audit-ready.
All prices in AUD, no GST charged · 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 of its kind, 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 — exposure monitoring, for example, is work for an occupational hygienist. The limits are set out at the front of every report.