The WHS system a tender panel, principal contractor or insurer asks to see: policy, plan, a 54-hazard risk register written for general jobbing shops, light engineering and maintenance bays, 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.
Different kind of business? See every industry
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: material receipt, storage and handling; cutting, grinding and material preparation; fit-up, tacking and assembly; welding - MIG (GMAW) and stick (MMA/SMAW) on bare mild steel; post-weld cleaning, finishing and inspection; 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 general jobbing shops, light engineering and maintenance bays actually do.
The hazard register is drawn from our welding and fabrication risk assessment: 54 hazards across 7 activities, each with its consequence and starting rating, and 422 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 general jobbing shops, light engineering and maintenance bays in New South Wales: WHS policy, management plan, the industry hazard and risk register (54 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 54 hazards in the welding and fabrication register, with the consequence and, where our calculator rates it, the starting risk given by a Certified Industrial Hygienist before any controls are counted.
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.
Zinc fume (metal fume fever), lead from old paint (a lead process with notification and biological monitoring duties), chromate primers containing Cr(VI), cadmium from plating, isocyanates from two-pack coatings. None of these are controlled by the arrangements in a bare mild steel workshop. Occupational Hygiene · inherent risk 4C.
Welding fumes are classified IARC Group 1 (carcinogenic to humans, lung cancer, with limited evidence for kidney cancer). Also occupational asthma, chronic bronchitis and reduced lung function. The exposure standard for welding fumes (not otherwise classified) is 1 mg/m3 as an 8-hour time weighted average, and this figure carries through into the Workplace Exposure Limits that apply from 1 December 2026. Occupational Hygiene · inherent risk 4C.
A general jobbing shop or maintenance bay in New South Wales does a little of everything in a single day. Stock arrives and is stored, it is cut and ground to size, fitted up and tacked, welded with MIG or stick on bare mild steel, then cleaned, finished and inspected before it leaves.
The hazard and risk register behind the plan holds 54 hazards and 422 controls. The ones that dominate it are forklift, crane and pedestrian movement on a shared floor, a dropped load when gantry or jib crane lifting gear fails, and the bandsaw, cut-off saw, drill, linisher and pedestal grinder that can deglove a hand or shatter a wheel. Toppling jigs and assemblies, sparks and slag igniting combustibles, and welding fume, which is classified IARC Group 1 with an exposure standard of 1 mg/m3 as an 8-hour average, sit alongside them.
A generic construction WHS plan is written for scaffolds, excavations and site traffic, so it says almost nothing about the things that hurt people in a jobbing shop. It will not treat welding fume as a health hazard with an exposure standard, it will not ask what is on incoming stock, and it has no answer for a job that arrives galvanised, painted with old lead paint or primed with a chromate coating. Those residues bring zinc fume, lead process duties, hexavalent chromium, cadmium and isocyanates that bare mild steel arrangements do not control.
Reviewers of a small fabrication business usually start with the signed WHS policy, because an unsigned or undated policy tells them the plan was never adopted. They then go straight to the hazard register to see whether welding fume, crane lifts and fixed plant guarding are rated and controlled, rather than listed in a single line. The register gives each hazard a starting rating and required controls.
Because welding fume and coated stock are health hazards, a careful reviewer looks for how exposure is managed over time and where health monitoring fits, including the lead process triggers that apply if old painted steel is worked. Insurers tend to read the emergency plan and the hot work arrangements, given that spatter and slag fires can take the premises and stock. Principal contractors want the contractor section, which sets out prequalification, induction and supervision, and the tender cover sheet points each panel question to the page where it is answered.
The most common story is a council or facilities tender that you were well placed to win, returned because the WHS management plan box was answered with a SWMS and a toolbox talk record.
The second story happens on the floor itself. A beam comes off the jib crane because a sling was set at too wide an angle and nobody had written down how lifts are planned, or an apprentice grinds a length of galvanised pipe and goes home with metal fume fever. When you are asked afterwards what your procedure was, there is nothing written that shows the hazard had been thought about.
The third is the notifiable incident, a fire started by slag in a corner full of rags or a serious hand injury on the pedestal grinder. The regulator will want to see how you identified the risk, what controls you chose, who was trained and when your plant was last inspected. Without a plan and its registers, you are reconstructing that 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.