The WHS system a tender panel, principal contractor or insurer asks to see: policy, plan, a 56-hazard risk register written for exhaust replacement shops, auto body repairers and custom vehicle fabricators, procedures, registers and an emergency plan. Editable Word, written by a Certified Industrial Hygienist.
Authored to order for your business and quoted within one business day. When the pack for this industry is released it will be sold here as a download.
Request this plan — quote within one business dayTell us your business name, sites and the tender or client you are preparing for. A Certified Industrial Hygienist replies within one business day.
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The policy and plan govern the system; the register, procedures and registers are written for this industry from the hazard content we already hold for it.
✓The hazard register covers 7 activities: vehicle and material receipt, positioning and support; cutting, removal and material preparation; vehicle isolation and preparation for hot work; welding on vehicles and subassemblies; exhaust and muffler fabrication, fitting and finishing; gas, consumable and chemical handling and storage and more.
✓Editable Microsoft Word throughout, with your business name, ABN, sites and responsible people written in.
A WHS management plan is the document a council tender panel, a principal contractor or an insurer asks for before your SWMS: the policy, the responsibilities, the way hazards are found and controlled, and the registers that prove the system runs. A generic plan names none of the work exhaust replacement shops, auto body repairers and custom vehicle fabricators actually do.
The hazard register is drawn from our automotive panel and exhaust risk assessment: 56 hazards across 7 activities, each with its consequence and starting rating, and 440 controls ranked on the hierarchy of control.
The plan is authored to order for your business by a Certified Industrial Hygienist and quoted within one business day. When the pack for this industry is released it will be sold here as an editable Word download.
WHS management plan for exhaust replacement shops, auto body repairers and custom vehicle fabricators in New South Wales: WHS policy, management plan, the industry hazard and risk register (56 hazards), safe work procedures, induction, inspection, incident and emergency registers, and a tender and prequalification cover sheet. Editable Word.
Authored to order for your business and quoted within one business day. When the pack for this industry is released it will be sold here as a download.
Request this plan — quote within one business dayTell us your business name, sites and the tender or client you are preparing for. A Certified Industrial Hygienist replies within one business day.
Different kind of business? See every industry
A sample of the 56 hazards in the automotive panel and exhaust register, with the consequence and, where our calculator rates it, the starting risk given by a Certified Industrial Hygienist before any controls are counted.
Uncommanded deployment with explosive force directly at the worker's head and hands, and modules or inflators becoming projectiles. Inflators can deploy from heat alone, with no electrical trigger and with the battery disconnected. Process Safety · inherent risk 5B.
Fuel vapour explosion, which destroys the vehicle and the bay; gas strut rupture, which fires the rod like a projectile; and phosgene and hydrogen fluoride from refrigerant decomposed by the arc, both of which cause delayed and serious lung injury. Process Safety · inherent risk 5B.
Crush injuries, multiple fractures, fatality. Vehicle and mobile plant incidents are consistently among the leading mechanisms of work-related fatality in Australia. Safety · inherent risk 4C.
Load dropped onto a person: crush injuries, multiple fractures, fatality. Sling angle is the most common miscalculation, because working load limit falls sharply as the included angle opens up. Safety · inherent risk 4C.
Entanglement and degloving, amputation of fingers and hands, severe lacerations; a workpiece drawn into the gap between wheel and work rest can shatter the wheel and eject fragments at lethal speed. Safety · inherent risk 4C.
Crush injuries and fatality; damage to the assembly and adjacent plant. Safety · inherent risk 4C.
Rapidly developing workshop fire, burns, loss of premises and stock, business interruption. Process Safety · inherent risk 4C.
Workshop fire, flash fire, explosion of a closed vessel, severe burns, fatality, loss of premises and stock. Process Safety · inherent risk 4C.
An exhaust replacement shop, auto body repairer or custom vehicle fabricator receives vehicles and material, positions and supports them, cuts and removes damaged or worn sections, isolates and prepares the vehicle for hot work, welds on the vehicle and on subassemblies, and fabricates, fits and finishes exhaust and muffler systems. Gas, consumables and chemicals are handled daily, and the workshop ventilation carries the fume from every bay. A plan for this business has to reflect that almost all of the hot work happens on a complete, fuelled car.
The register for this trade holds 56 hazards and 440 controls, and the two most severe come from the vehicle itself. Airbags, seatbelt pretensioners and other pyrotechnic devices can deploy from heat alone, with no electrical trigger and with the battery disconnected, firing modules at the worker's head and hands. Fuel, gas struts and air conditioning systems turn cutting and welding into a risk of vapour explosion, a strut rod fired like a projectile, and phosgene and hydrogen fluoride from refrigerant decomposed by the arc. Spatter and hot fragments igniting combustibles, forklift and crane movements, fixed workshop plant and unstable assemblies fill out the upper part of the register.
A generic construction WHSMP has no vocabulary for a car on a hoist. It will not tell a technician to locate and protect pyrotechnic devices before heating a pillar, to treat an air conditioning line as a toxic gas source, or to deal with a fuel tank before cutting near the rear of a vehicle. Those are the procedures that matter in your bays.
Insurers and repair networks tend to start with the signed WHS policy, then look at how hot work on vehicles is controlled, because fire and airbag deployment are the events that generate the largest claims. The plan gives them the rated register entries for pyrotechnic devices, fuel and refrigerant, the vehicle isolation and hot work procedures that sit behind them, and an emergency plan with a drill record.
Fleet operators and councils sending vehicles for body or exhaust work read the same sections, and also check how health hazards are handled. Because arc decomposition of refrigerant produces gases that cause delayed lung injury, reviewers look for how exposure is assessed and how any health monitoring is arranged within your risk process. Where you use mobile auto electricians, glaziers or tow operators, the contractor section shows how they are prequalified, inducted and supervised on your premises. The tender cover sheet tells a panel where each of its requirements is answered.
A fleet maintenance contract or a council panel for vehicle body and exhaust work asks every applicant for a WHS management plan. A shop that sends a public liability certificate and a page of workshop rules is screened out at compliance, however good its work and turnaround are.
Repair networks and larger clients increasingly ask the same question at onboarding. When their assessor visits and asks how your technicians make an airbag system safe before heating a panel, the honest answer cannot be that everyone just knows. Without a written procedure and a training record, the onboarding stalls and the referral work goes to another shop.
The worst case is an event in your own bay. A curtain airbag deploys while a technician is heating a roof rail, or a fuel line ignites during exhaust cutting and the fire reaches the building. The regulator will want the risk assessment, the procedure the technician was following, the record that they were trained in it and the incident register for your workshop. If none of it existed before the day, you are left explaining your controls with nothing written to support the due diligence you believe you had.
If you operate, maintain or contract to these assets in NSW, this pack is written for your duties.
The Codes of Practice and Australian Standards these documents are measured against, and the legislation behind them.
Send the enquiry with your business name and the tender or client you are preparing for. You will have an itemised quote within one business day and a plan written for your work, not a template with the name changed.
Authored to order for your business and quoted within one business day. When the pack for this industry is released it will be sold here as a download.
A WHS management plan supports your due diligence; holding one is not compliance in itself. You must run the system it describes — consult your workers, put the controls in place, keep the registers current and review the plan after any incident or change. Exposure monitoring and health monitoring, where the register calls for them, are work for an occupational hygienist and a registered medical practitioner.