The WHS system a tender panel, principal contractor or insurer asks to see: policy, plan, a 10-hazard risk register written for hard rock quarries and mobile crushing and screening operators, 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.
✓Built on the quarry pack's 7 control documents, including master SOP; explosives Handling, Blast Design & Shotfiring Safety Standard; respirable Crystalline Silica (RCS) Health Monitoring & Exposure Control Protocol.
✓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 hard rock quarries and mobile crushing and screening operators actually do.
The hazard register is drawn from our quarry compliance pack: 10 leading hazards, each with the control documents that answer it.
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 hard rock quarries and mobile crushing and screening operators in New South Wales: WHS policy, management plan, the industry hazard and risk register (10 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 10 hazards in the quarry register, with the consequence and, where our calculator rates it, the starting risk given by a Certified Industrial Hygienist before any controls are counted.
Uncontrolled rock projection beyond blast perimeter or stemming blow-out strikes plant, light vehicles, or personnel; catastrophic blunt force trauma or fatalities.
Inhalation of micro-quartz particles (<10 µm) leading to irreversible silicosis, pulmonary fibrosis, lung cancer, and chronic obstructive pulmonary disease (COPD).
Brake failure, soft road edge collapse, or visibility blind spots result in 50t+ haul truck crushing light vehicle or overturning over a haul road bench.
Worker entering feed hopper or using handheld pry-bars to dislodge oversized rock; sudden collapse or inadvertent crusher start causes fatal entrapment and crushing.
Geotechnical joint slip or rain-induced structural failure causes hundreds of tonnes of rock to fall onto excavators or drill rigs operating below.
Worker drawn into return rollers, tail drums, or transfer chute conveyors during manual belt cleaning or alignment while plant is running.
Reclaim tunnel collapse or vertical stockpile undermining causes sudden bulk aggregate slide, burying earthmoving plant or operators.
Excavator bucket impacts undetonated booster or electronic detonator in rock muck-pile, causing accidental secondary explosion.
A hard rock quarry runs a chain of high-energy work every shift: pattern drilling and shotfiring, loading the muck-pile, hauling on benched roads, primary and secondary crushing, screening and conveying, and road load-out. Mobile crushing and screening operators carry the same chain from site to site. The plan has to hold the statutory roles of quarry manager and site senior executive, a daily-to-annual compliance calendar, permit-to-work interfaces, pre-start plant audits, contractor management and management of change.
The risk register is led by a short list of things that kill people in pits. Flyrock and blast overpressure reach beyond the perimeter. Misfires wait in the muck-pile for an excavator bucket. Haul trucks roll over soft edges or crush light vehicles in blind spots. Highwalls and bench crests fail after rain, stockpiles slump onto loaders, and workers climb into a bridged crusher hopper or reach into conveyor nip points while the plant is running. Behind all of it sits respirable crystalline silica from drilling, crushing and screening granite, basalt, quartzite and rhyolite.
A generic construction WHSMP has nowhere to put any of this. It has no blast exclusion or misfire clearance procedure, no haul road berm and intersection rules, no highwall inspection or face scaling protocol, no zero-energy lockout for crushers and screens, and no silica monitoring and health surveillance under Part 8.8A of the WHS Regulation 2025 (NSW). A quarry plan starts from those.
A council buying aggregate, or a principal bringing a mobile crushing crew onto its site, opens the signed WHS policy first and then goes straight to the hazards that worry them most. For a pit that is usually blasting and flyrock, haul road traffic around their own trucks, and face stability. The plan gives them a register that names each hazard, its starting rating and the controls required, cross-referenced to the safe work procedures behind it.
Because silica is a health hazard at every quarry, reviewers look for air monitoring and health surveillance records, not just a line about dust masks. The plan sets out where sampling sits and how the surveillance register is kept. Contractor management shows how drillers, shotfirers and haulage subcontractors are prequalified, inducted and supervised, and the emergency plan with its drill record shows what happens after a blast incident, a rollover or a rockfall. The tender cover sheet points each panel question to the page that answers it.
The common first failure is commercial. A council supply tender asks for a WHS management plan and evidence of silica controls, and you send a folder of pre-start checklists. The panel marks the submission non-conforming and the contract goes to a quarry down the road that sent a plan. A principal stops your crushing crew at the induction when it cannot show how conveyor isolation is managed.
The second failure happens on the bench. A loader driver is sent to clear a bridged hopper with a pry-bar because that is how it has always been done, or an operator walks the conveyor to knock off build-up with the belt still turning. Nobody wrote down that this task needs isolation, so nobody checked. When the injury happens, your supervisors are asked which procedure applied and there is none to show.
The third is the conversation with the regulator after a notifiable incident: a flyrock strike outside the exclusion zone, a misfire found by an excavator, a truck over a berm. The inspector asks for the blast design, the exclusion records, the haul road standard and the training register. A written plan with its registers supports your due diligence case; its absence leaves your site explaining practice from memory.
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.