Introduction to Safe Management
of Plant
HEALTH AND SAFETY SERVICES
Introduction
Plant is a major cause of workplace death or injury in Australia.
The Work Health and Safety Act 2012 and Work Health and Safety Regulations 2012
have significant plant and structure safety requirements.
HEALTH AND SAFETY SERVICES
Definition of Plant
Any machinery, equipment, appliance, container, implement and tool, and includes
any component or anything fitted or connected to any of those things.
Certain kinds of plant, such as forklifts, cranes and some pressure equipment,
require a licence from the WHS regulator to operate and some high-risk plant must
also be registered with the WHS regulator.
HEALTH AND SAFETY SERVICES
Definition of Structure
Is anything that is constructed, whether fixed or moveable, temporary or permanent
and includes buildings, masts, towers, framework, pipelines, transport infrastructure
and underground works, any component of a structure and part of a structure.
HEALTH AND SAFETY SERVICES
Registration and Licencing of Plant and Structures
Some plant must be registered with SafeWork SA before it can be supplied (at design)
or before it can be used (management or control).
Some plant require the operator to hold a high risk work licence before it can be
operated.
HEALTH AND SAFETY SERVICES
The Principles of Safe Plant Management
All hazards and risks to health and safety as a result of using plant are managed in
accordance with risk management principles covering the full life cycle of plant.
Design
Manufacture
Import /
Supply
HEALTH AND SAFETY SERVICES
Pre purchase
Install
Use
Dispose
Duties
PCBU
Primary duty to ensure, so far as is reasonably practicable, that workers and other persons
are not exposed to health and safety risks arising from the business or undertaking. This
includes:
• The provision and maintenance of safe plant; and
• The safe use, handling, storage and transport of plant.
PCBU with
management or
control of plant
Also have a duty to:
• Manage the health and safety risks associated with plant.
• Prevent unauthorised alterations to or interference with plant.
• Use plant only for the purpose for which it was designed unless the proposed use does not
increase the risk to health and safety.
Officers
Duty to exercise due diligence to ensure that the PCBU complies with the WHS Act and
Regulations. This includes taking reasonable steps to ensure that the PCBU has and uses
appropriate resources and processes to eliminate or minimise risks that arise from plant used
in the workplace.
Workers
Duty to take reasonable care for their own health and safety and must not adversely affect
the health and safety of other persons. Workers must comply with any reasonable
instruction and cooperate with any reasonable policy or procedure relating to health and
safety at the workplace.
HEALTH AND SAFETY SERVICES
Duty Holders
DESIGNERS
P
C
B
U
MANUFACTURERS
IMPORTERS AND SUPPLIERS
(Hirers and Leasers)
SUPPLIERS OF SECOND HAND PLANT
(Internal transfers within workplaces)
INSTALL, CONSTRUCT OR
COMMISSION PLANT OR STRUCTURES
MANAGEMENT OR CONTROL OF
PLANT AT A WORKPLACE
HEALTH AND SAFETY SERVICES
Duty Holders
DESIGNERS
P
C
B
U
MANUFACTURERS
IMPORTERS AND SUPPLIERS
(Hirers and Leasers)
SUPPLIERS OF SECOND HAND PLANT
(Internal transfers within workplaces)
INSTALL, CONSTRUCT OR
COMMISSION PLANT OR STRUCTURES
MANAGEMENT OR CONTROL OF
PLANT AT A WORKPLACE
HEALTH AND SAFETY SERVICES
• Eliminate or minimise risks at design
stage where practicable
• Comply with specified requirements eg.
guarding
• Provide information about the plant
such as hazards and risks associated
with the use, testing, inspections and
emergency response requirements.
Duty Holders
DESIGNERS
P
C
B
U
MANUFACTURERS
IMPORTERS AND SUPPLIERS
(Hirers and Leasers)
SUPPLIERS OF SECOND HAND PLANT
(Internal transfers within workplaces)
INSTALL, CONSTRUCT OR
COMMISSION PLANT OR STRUCTURES
MANAGEMENT OR CONTROL OF
PLANT AT A WORKPLACE
HEALTH AND SAFETY SERVICES
• Inform the designer of any hazards
identified during manufacture.
• If this is not possible, the manufacturer
is required to eliminate or control the
risk.
• Provide information about the plant eg.
information about the hazards, to the
person who is supplied the plant.
Duty Holders
DESIGNERS
P
C
B
U
MANUFACTURERS
IMPORTERS AND SUPPLIERS
(includes Hirers and Leasers)
SUPPLIERS OF SECOND HAND PLANT
(Internal transfers within workplaces)
INSTALL, CONSTRUCT OR
COMMISSION PLANT OR STRUCTURES
MANAGEMENT OR CONTROL OF
PLANT AT A WORKPLACE
HEALTH AND SAFETY SERVICES
• Obtain information about the plant
from the manufacturer eg. hazards,
risk assessments , control measures,
operator /user manuals and
instructions, construction, installation,
erection, commissioning plans,
records from previous owners.
• Provide this information to the person
who is supplied the plant eg. safety
records, inspection reports,
maintenance, repair and any
modifications to the plant.
Duty Holders
DESIGNERS
P
C
B
U
MANUFACTURERS
IMPORTERS AND SUPPLIERS
(Hirers and Leasers)
SUPPLIERS OF SECOND HAND PLANT
(Internal transfers within workplaces)
INSTALL, CONSTRUCT OR
COMMISSION PLANT OR STRUCTURES
MANAGEMENT OR CONTROL OF
PLANT AT A WORKPLACE
HEALTH AND SAFETY SERVICES
Through sale, loan, trade-in, transfer or
donation must:
• Identify any faults in the plant.
• Provide information in writing to the
person who is supplied the plant
about:
- The condition of the plant.
- Any identified faults.
- Notice that the plant should not be
used until faults have been fixed.
Duty Holders
DESIGNERS
P
C
B
U
MANUFACTURERS
IMPORTERS AND SUPPLIERS
(Hirers and Leasers)
SUPPLIERS OF SECOND HAND PLANT
(Internal transfers within workplaces)
INSTALL, CONSTRUCT OR
COMMISSION PLANT OR STRUCTURES
MANAGEMENT OR CONTROL OF
PLANT AT A WORKPLACE
HEALTH AND SAFETY SERVICES
A competent or licensed person installs,
constructs or commissions plant and
structures in accordance with information
provided by the designer, manufacturer,
importer or supplier of the plant or
structure.
Duty Holders
DESIGNERS
P
C
B
U
MANUFACTURERS
IMPORTERS AND SUPPLIERS
(Hirers and Leasers)
SUPPLIERS OF SECOND HAND PLANT
(Internal transfers within workplaces)
INSTALL, CONSTRUCT OR
COMMISSION PLANT OR STRUCTURES
MANAGEMENT OR CONTROL OF
PLANT AT A WORKPLACE
HEALTH AND SAFETY SERVICES
• Risks are manages in accordance with
risk management requirements.
• Control measurers are implemented
before installation or commissioned
into use eg. guarding, e-stops.
• Unauthorised interference with or
alteration to plant is prevented.
• Plant is only used for its intended
purpose
• Risks associated with proposed use is
assessed by a competent person.
• Guards, e-stops and warning devices
are in place and operational.
• Safety features and warning devices
are used.
• Plant does not create a risk to health
and safety when not in use.
• Maintenance, inspection, repair and
testing is only carried out by a
competent person.
Duty to Consult
Design, manufacture and use of plant may involve several PCBUs.
 Where several PCBUs have duties on same matter, they must consult, co-operate
and co-ordinate activities with each other on the matter.
 Duty to consult workers who may be affected.
HEALTH AND SAFETY SERVICES
Alterations to or Interference with Existing Plant
Risk assessments must be undertaken to determine potential impacts on existing
operations and the health and safety of workers:
 Prior to any alteration or modification to existing plant.
 A change in the way plant is used or a system of work associated with the plant.
 A change in the location of the plant.
Alterations or modifications, including the removal of guarding or interference with
emergency stop controls or warning devices must not be undertaken without the
site manager’s approval.
HEALTH AND SAFETY SERVICES
Decommissioning, Dismantling and Disposing of Plant
Plant can be identified as suitable for disposal because:
 It is no longer required due to change in workplace, procedure, function or
activity.
 It no longer complies with WHS legislation, Australian Standards or DECD
specifications.
 It is beyond economical repair and is suitable for scrap or spare parts only.
HEALTH AND SAFETY SERVICES
Decommissioning, Dismantling and Disposing of Plant
The process occurs in accordance with manufacturer’s instructions and is managed
by a competent person.
It complies with the requirements of Regulation 204 of the WHS Regulations 2012
to ensure that any hazards inherent in the process of decommissioning, dismantling
or disposal have been identified and controlled.
If the plant contains materials which are likely to present a risk to the health and
safety of individuals or to the environment (eg. asbestos or a hazardous chemical),
the material is disposed of in accordance with relevant regulatory requirements.
HEALTH AND SAFETY SERVICES
Hazard Identification and Risk Assessment
Detailed information on the identification of hazards, risk assessment process and
control measures are provided in:
 DECD Guidelines for the Safe Use of Machinery.
 Managing the Risks of Plant in the Workplace Code of Practice.
Where a hazard has been identified a risk assessment must be undertaken using
the Plant Risk Assessment Form in consultation with affected workers.
HEALTH AND SAFETY SERVICES
Control Measures
Elimination
Substitution
Isolation
Engineering
Administration
PPE
HEALTH AND SAFETY SERVICES
Approved Codes of Practice relating to Plant
SafeWork Australia has drafted a number of Approved Codes of Practices relevant to
plant safety:
 How to manage work health and safety risks
 Managing risks of plant in the workplace
Draft Codes of Practice pending:
 Safe design, manufacture, import a d supply of plant
 Managing risks of plant in rural workplaces
HEALTH AND SAFETY SERVICES
Role of Approved Codes of Practice
National Codes must be approved by the Minister to become ACOP.
Admissible in court as evidence whether duty under the Act has been complied with.
Court may have regard to ACOP:
 On what is known about a hazard or risk or risk control.
 To determine what is reasonably practicable in the circumstances.
Evidence may be provided as compliance in a manner that is different from what is
outlined in an ACOP – but the standard must be equal or better .
HEALTH AND SAFETY SERVICES
Reasonably Practicable
Seriousness of
harm
(Death or
disability)
Likelihood of
hazard or risk
occurring
HEALTH AND SAFETY SERVICES
Knowledge
about the risks
(What you know
or should know)
Availability or
suitability of ways
to eliminate or
minimise risks
REASONABLY
PRACTICABLE
Cost
Use
Plant must used only for the purpose it was designed and is operated in accordance
with manufacturer’s instructions.
Safe work zones are established.
Guards and e-stops must not be removed or tampered with.
Safety Operating Procedures (SOPS) are placed in close proximity to the plant.
Personal Protective Equipment suitable to the task is used where required.
When plant is not in use for 3 months or more, an OUT OF SERVICE tag must be
attached and plant is locked out where possible.
HEALTH AND SAFETY SERVICES
Maintenance and Inspection
Site Maintenance Schedules are to be maintained for all plant.
Isolation or lock out systems to be used when inspecting, testing or performing
maintenance or repairs to high risk plant in accordance with DECD specifications.
Testing and tagging of electrical plant is to be undertaken in accordance with DECD
Electrical Testing Procedure.
Activities are undertaken by a competent person.
HEALTH AND SAFETY SERVICES
Record Keeping
WHS Regulations has prescriptive record keeping requirements for:
 Maintenance, testing records of plant subject to design or item registration with
SafeWork SA - life of plant.
 Presence sensing safeguarding systems – 5 years.
DECD requires site managers to keep records for plant in their management or
control
 For the life of the plant.
 Or until control is relinquished.
HEALTH AND SAFETY SERVICES
http://www.decd.sa.gov.au/hrhealthsafety/
Phone: 8226 7555
HEALTH AND SAFETY SERVICES