The WHS system a tender panel, principal contractor or insurer asks to see: policy, plan, a 57-hazard risk register written for heavy engineering plants, crusher and chute fabricators and structural boiler shops, 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: heavy plate and section receipt, storage and handling; cutting, bevelling and heavy material preparation; heavy fit-up, support and manipulation; welding, gouging and preheat on thick section; repair of boilers, fired plant and lagged equipment; 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 heavy engineering plants, crusher and chute fabricators and structural boiler shops actually do.
The hazard register is drawn from our boilermaking risk assessment: 57 hazards across 7 activities, each with its consequence and starting rating, and 452 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 heavy engineering plants, crusher and chute fabricators and structural boiler shops in New South Wales: WHS policy, management plan, the industry hazard and risk register (57 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 57 hazards in the boilermaking register, with the consequence and, where our calculator rates it, the starting risk given by a Certified Industrial Hygienist before any controls are counted.
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. Occupational Hygiene · inherent risk 5C.
Burns from contact with surfaces that look cool, heat stress and collapse inside a space from which retrieval is difficult, and falling refractory. Entry into fired plant is confined space entry whether or not anyone calls it that. Safety · inherent risk 5B.
Asbestos exposure from lagging, gaskets and linings on older plant, with no safe level and licensed removal duties. Refractory ceramic fibre is a respiratory irritant and suspected carcinogen, and after firing also releases cristobalite, a form of respirable crystalline silica. Occupational Hygiene · 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.
Heavy engineering plants, crusher and chute fabricators and structural boiler shops move heavy plate and section from delivery onwards. Material is cut and bevelled, heavy fit-up needs support and manipulation, and thick sections are welded, gouged and preheated. Many of these shops also repair boilers, fired plant and lagged equipment, which brings old insulation and hot internals into the workshop. Gases, consumables and chemicals are stored and handled throughout, so the plan has to cover both new fabrication and repair.
The hazard and risk register holds 57 hazards and 452 controls. Air arc gouging fume and noise is rated 5C as the highest single-task exposure on the floor: a short 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. Residual heat and confined entry in fired plant, and lagging, refractory and insulation that may contain asbestos or release cristobalite after firing, are both rated 5B. Mobile plant, cranes, fixed plant, toppling work and sparks complete the leading list.
A generic construction WHS plan does not anticipate repair of fired plant. It will not recognise that entering a boiler is confined space entry whatever it is called on the day, it will not ask whether the lagging is asbestos before anyone cuts it, and it leaves gouging out of exposure assessment because gouging is rework. In this trade those are the omissions that do lasting harm.
Clients sending boilers, chutes and crushers for repair usually open the signed policy and then the parts of the hazard register that concern their equipment: fired plant entry and lagged components. The plan rates both and sets out how asbestos is identified before work, how licensed removal duties are handled, and how entry to fired plant is controlled and rescued.
Because gouging fume, noise, asbestos and cristobalite are health hazards, reviewers look for health monitoring and how long-term exposure is tracked. Insurers commonly read the emergency plan and the hot work arrangements. The contractor section covers prequalification, induction and supervision of licensed removalists, riggers and labour hire, and the tender cover sheet directs each panel to where its requirement is answered.
Mining, power and processing clients usually require a documented WHS system before they send repair work off site. If your shop cannot show a management plan that covers fired plant, asbestos and confined entry, you are left off the panel, however good your welders are, and the repair goes to a workshop that can.
On your floor, the damaging event is often invisible at first. A fitter strips old lagging from a boiler door to get at a crack, and only later is it found to contain asbestos. You are then asked whether the material was checked, who was exposed and what the procedure said, and without an asbestos procedure and a register of who worked on the job, there is little you can put forward.
Entry to fired plant creates the sudden version of the same problem. A worker goes into a boiler that looks cool, is overcome by heat or struck by falling refractory, and a rescue has to be improvised. When the notifiable incident is reported, the regulator will ask for the entry procedure, the rescue arrangement and the training record, and a verbal account of how it is usually done will not satisfy anyone.
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.