Safe Design, Manufacture, Import
and Supply of Plant
Draft
Code of Practice
SAFE W
Table of Contents
FOREWORD ............................................................................................................. 4
SCOPE AND APPLICATION .................................................................................... 4
1
INTRODUCTION................................................................................................ 5
1.1
The meaning of key terms .......................................................................... 5
1.2
Who has health and safety duties in relation to plant?................................ 6
1.3
What is required to manage health and safety risks associated with plant? 6
2
HOW TO MANAGE PLANT RISKS ................................................................... 9
2.1
Identifying hazards ..................................................................................... 9
2.2
Assessing the risks .................................................................................. 10
2.3
Controlling the risks ................................................................................. 10
2.4
Reviewing risk control measures .............................................................. 11
2.5
Information sources ................................................................................. 11
3
SAFE DESIGN OF PLANT .............................................................................. 13
3.1
What is safe design? ................................................................................ 13
3.2
The role of designers ............................................................................... 13
3.3
Integrating safe design and risk management .......................................... 14
3.4
Pre-design and concept development phase ........................................... 14
3.5
Design phase ........................................................................................... 16
3.6
Testing and examination of plant ............................................................. 17
3.7
Providing information ............................................................................... 17
3.8
Registering plant design........................................................................... 19
4
DESIGN CONSIDERATIONS .......................................................................... 21
4.1
Physical characteristics of users .............................................................. 21
4.2
Design to facilitate safe use ..................................................................... 21
4.3
Reasonably foreseeable misuse .............................................................. 22
4.4
Minimising human error............................................................................ 22
4.5
Environmental conditions ......................................................................... 22
4.6
Erection and installation ........................................................................... 22
4.7
Maintenance ............................................................................................ 23
4.8
Guarding .................................................................................................. 23
4.9
Operator control devices .......................................................................... 25
4.10 Emergency stops ..................................................................................... 26
4.11 Failure of the control circuit ...................................................................... 27
4.12 Warning devices ...................................................................................... 27
5
MANUFACTURE OF PLANT ........................................................................... 28
5.1
The role of manufacturers ........................................................................ 28
5.2
Plant construction .................................................................................... 28
5.3
Testing and examination of plant ............................................................. 29
5.4
Information about the safe use of plant .................................................... 30
5.5
Registration of plant design ...................................................................... 30
5.6
Item registration ....................................................................................... 30
6
IMPORT AND SUPPLY OF PLANT ................................................................. 31
6.1
Examination and testing of plant .............................................................. 31
6.2
Information about the safe use of plant .................................................... 31
6.3
Compatibility of plant ................................................................................ 31
6.4
Imported plant .......................................................................................... 32
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6.5
6.6
6.7
7
Design registration ................................................................................... 32
Hire of plant ............................................................................................. 32
Second-hand plant ................................................................................... 33
SPECIFIC RISK CONTROLS .......................................................................... 35
7.1
Confined spaces ...................................................................................... 35
7.2
Manual tasks............................................................................................ 35
7.3
Noise ....................................................................................................... 36
7.4
Energy sources ........................................................................................ 36
7.5
Static electricity ........................................................................................ 37
7.6
Lightning .................................................................................................. 37
7.7
Fire and explosion.................................................................................... 37
7.8
Plant capable of entangling an operator ................................................... 37
7.9
Vibration .................................................................................................. 38
7.10 Exposure to radiation ............................................................................... 38
7.11 Risk of being trapped ............................................................................... 39
7.12 Hazardous chemicals ............................................................................... 39
7.13 Combined plant ........................................................................................ 40
7.14 Stability .................................................................................................... 40
7.15 Mechanical or structural failure during operation ...................................... 40
7.16 Software .................................................................................................. 41
7.17 Lighting .................................................................................................... 41
APPENDIX A – EXAMPLES OF TECHNICAL STANDARDS ................................. 42
APPENDIX B – REGISTRABLE PLANT ................................................................. 46
APPENDIX C – DESIGN SOURCES OF HUMAN ERROR ..................................... 48
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FOREWORD
This Code of Practice on the safe design, manufacture, import and supply of plant is an
approved code of practice under section 274 of the Work Health and Safety Act (the WHS
Act).
An approved code of practice is a practical guide to achieving the standards of health, safety
and welfare required under the WHS Act and the Work Health and Safety Regulations (the
WHS Regulations).
A code of practice applies to anyone who has a duty of care in the circumstances described
in the code. In most cases, following an approved code of practice would achieve
compliance with the health and safety duties in the WHS Act, in relation to the subject matter
of the code. Like regulations, codes of practice deal with particular issues and do not cover
all hazards or risks which may arise. The health and safety duties require duty holders to
consider all risks associated with work, not only those for which regulations and codes of
practice exist.
Codes of practice are admissible in court proceedings under the WHS Act and Regulations.
Courts may regard a code of practice as evidence of what is known about a hazard, risk or
control and may rely on the code in determining what is reasonably practicable in the
circumstances to which the code relates.
Compliance with the WHS Act and Regulations may be achieved by following another
method, such as a technical or an industry standard, if it provides an equivalent or higher
standard of work health and safety than the code.
An inspector may refer to an approved code of practice when issuing an improvement or
prohibition notice.
This Code of Practice has been developed by Safe Work Australia as a model code of
practice under the Council of Australian Governments’ Inter-Governmental Agreement for
Regulatory and Operational Reform in Occupational Health and Safety for adoption by the
Commonwealth, state and territory governments.
A draft of this Code of Practice was released for public consultation on 2 April 2012 and was
endorsed by the Select Council for Workplace Relations on [to be completed].
SCOPE AND APPLICATION
This Code provides practical guidance for persons conducting a business or undertaking
who design (including redesign or modification of a design), manufacture, import or supply
plant that is used, or could reasonably be expected to be used, at a workplace on how to
meet the requirements under the WHS Act and Regulations.
The Code of Practice: Managing Risks of Plant on the Workplace provides guidance on how
to manage health and safety risks of plant once it is in the workplace, from installation,
commissioning and use through to decommissioning and dismantling.
How to use this code of practice
In providing guidance, the word ‘should’ is used in this Code to indicate a recommended
course of action, while ‘may’ is used to indicate an optional course of action.
This Code also includes various references to provisions of the WHS Act and Regulations
which set out the legal requirements. These references are not exhaustive. The words
‘must’, ‘requires’ or ‘mandatory’ indicate that a legal requirement exists and must be
complied with.
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1
INTRODUCTION
Plant is a major cause of workplace death and injury in Australian workplaces. There are
significant risks associated with using plant and severe injuries can result, including:
 limbs amputated by unguarded moving parts of machines
 being crushed by mobile plant
 sustaining fractures from falls while accessing, operating or maintaining plant
 electric shock from plant that is not adequately protected or isolated
 burns or scalds due to contact with hot surfaces, or exposure to flames or hot fluids.
Other risks include hearing loss due to noisy plant and musculoskeletal disorders caused by
manually handling or operating plant that is poorly designed. Designers, manufacturers,
importers and suppliers have an important role in ensuring, so far as is reasonably
practicable, that the plant they design, manufacture, import or supply is safe before it is
introduced and used in the workplace.
1.1 The meaning of key terms
Plant includes any machinery, equipment, appliance, container, implement and tool, and
includes any component or anything fitted or connected to any of those things. Plant
includes items as diverse as lifts, cranes, computers, machinery, conveyors, forklifts,
vehicles, power tools and amusement devices.
Plant that relies exclusively on manual power for its operation and is designed to be primarily
supported by hand, for example a screw driver, is not covered by the WHS Regulations. The
general duty of care under the WHS Act applies to this type of plant.
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.
Competent person means a person who has acquired through training, qualification or
experience the knowledge and skills to carry out the task.
A competent person has a more specific meaning in the following circumstances:

For design verification, the person must have the skills, qualifications, competence
and experience to design the plant or verify the design.

For inspection of plant for registration purposes the person must have:
o educational or vocational qualifications in an engineering discipline relevant to
the plant being inspected, or
o knowledge of the technical standards relevant to the plant being inspected.

For inspection of mobile cranes, tower cranes and amusement devices the person
must:
o have the skills, qualifications, competence and experience to inspect the
plant, and
be registered under a law that provides for the registration of professional
engineers (in jurisdictions where such a law exists), or
o be determined by the WHS regulator to be a competent person.
Fail safe means a state or condition where, if any component or function of the plant fails, a
system exists to prevent any increase in the risks. For example, if the primary hoist brake
fails on a crane lifting a person in a workbox, the secondary hoist brake will prevent
uncontrolled dropping of the workbox. However, once the secondary brake is engaged, a
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lower level of safety has been reached. The situation must be made safe and the fault
rectified so that the fail safe capability is re-established.
The reliability or safety integrity of the fail safe system should be commensurate with the
determined level of risk (for example, Category 1 to Category 4 applied in AS 4024: Safety of
Machinery).
1.2 Who has health and safety duties in relation to plant?
A person conducting a business or undertaking has the primary duty under the WHS Act
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 duty
includes ensuring, so far as is reasonably practicable:
 the provision and maintenance of safe plant, and
 the safe use, handling, storage and transport of plant.
Persons who conduct a business or undertaking involving the management or control
of fixtures, fittings or plant at a workplace must ensure, so far as is reasonably
practicable, that the fixtures, fittings and plant are without risks to the health and safety of
any person.
Designers, manufacturers, suppliers, importers and installers of plant must also ensure,
so far as is reasonably practicable, that the plant they design, manufacture, import, supply or
install is without risks to health and safety.
The WHS Regulations include more specific duties for designers, manufacturers, importers
and suppliers of plant in relation to the risks of confined spaces, noise and musculoskeletal
disorders.
As there are generally a number of people involved with plant during its lifecycle (i.e. from its
design through to its use and eventual disposal), a person can have more than one duty and
more than one person can have the same duty at the same time.
In some circumstances, a manufacturer, importer or supplier of plant will also have the
duties of a designer.
Officers, for example, company directors, have a duty to exercise due diligence to ensure
that the business or undertaking complies with the WHS Act and Regulations. This includes
taking reasonable steps to ensure that the business or undertaking has and uses
appropriate resources and processes to eliminate or minimise risks that arise from plant
used in the workplace.
Workers have a 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.
1.3
What is required to manage health and safety risks associated with plant?
R. 34-38: In order to manage risk under the WHS Regulations, a duty holder must:
 identify reasonably foreseeable hazards that could give rise to the risk
 eliminate the risk so far as is reasonably practicable
 if it is not reasonably practicable to eliminate the risk, minimise the risk so far as is
reasonably practicable by implementing control measures in accordance with the
hierarchy of control
 maintain the implemented control measure so that it remains effective
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
review, and if necessary revise, risk control measures so as to maintain, so far as is
reasonably practicable, a work environment that is without risks to health and safety.
This Code provides guidance on how to manage the risks associated with plant by following
a systematic process that involves:
 identifying hazards
 if necessary, assessing the risks associated with these hazards,
 implementing and maintaining risk control measures
 reviewing risk control measures.
Designers, manufacturers, importers and suppliers of plant should use this process as a way
of making plant as safe as possible before it is used in the workplace.
General guidance on the risk management process is available in the Code of Practice: How
to Manage Work Health and Safety Risks.
Providing and obtaining information
Designers, manufacturers, importers and suppliers all have obligations to provide
information about the plant to enable other duty holders to fulfil the responsibilities they have
in managing the risks associated with it. This information must be given to each person to
whom the plant (or its design) is provided. Information must be passed on from the designer
through to the manufacturer and supplier to the end user. This information includes:
 the purpose for which plant was designed or manufactured
 the results of any calculations, analysis, testing or examination, and
 any conditions necessary for the safe use of the plant.
Consulting workers
A person conducting a business or undertaking must consult, so far as is reasonably
practicable, with workers who carry out work for the business or undertaking who are (or are
likely to be) directly affected by a work health and safety matter.
If the workers are represented by a health and safety representative, the consultation must
involve that representative.
Consultation with workers and their health and safety representatives is required at each
step of the risk management process. If you are designing or modifying plant for use in your
own workplace, you must consult your workers so far as is reasonably practicable, as the
plant and the way it is used may affect their health and safety. Your workers may have
practical suggestions or potential solutions that can be included at the design stage.
Consulting, cooperating and coordinating activities with other duty holders
A person conducting a business or undertaking must consult, cooperate and coordinate
activities with all other persons who have a work health or safety duty in relation to the same
matter, so far as is reasonably practicable.
Often, many different businesses or undertakings are involved in the design, manufacture,
import and supply of an item of plant and their decisions may positively or negatively affect
the safety of the product. In these situations, each duty holder will have health and safety
responsibilities related to the safety of the plant.
Where it is reasonably practicable to do so, the duty holders involved must consult each
other on the risks associated with the plant and work together in a cooperative and
coordinated way to control the risks.
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Further guidance on consultation is available in the Code of Practice: Work Health and
Safety Consultation, Cooperation and Coordination.
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2
HOW TO MANAGE PLANT RISKS
2.1 Identifying hazards
Identifying hazards involves finding all of the things and situations that could potentially cause
harm to people. Hazards associated with plant generally arise from:
 The plant itself: For example, hazards associated with a forklift would include hazards
relating to its mobility, it’s electrical, hydraulic and mechanical power sources, its moving
parts, its load-carrying capacity and operator protection.
 How and where the plant is used: The forklift, for example, may have hazards arising from
the kind of loads it is used to lift, the size of the area in which it is used and the slope or
evenness of the ground.
Things to consider when looking for hazards
Possible kinds of hazard
 Could the plant cause injury due entanglement, crushing, trapping, cutting, stabbing,
puncturing, shearing, abrasion, tearing or stretching?
 Could the plant create hazardous conditions due to pressurised content, electricity, noise,
radiation, friction, vibration, fire, explosion, temperature, moisture, vapour, gases, dust,
ice, hot or cold parts?
 Could the plant cause injury or ill health due to poor ergonomic design?
Suitability
 How suitable would the plant be for its intended purpose? What could happen if it was
used for a purpose other than the intended purpose?
 How suitable are the materials used to make the plant?
 How suitable are any accessories to the plant? In what condition are they?
 How stable is the plant? Might it roll over?
 If the plant is intended to lift and move people, equipment or materials, how capable is it of
doing this? Will there be an effective back-up system to support the load?
Access
 What sort of access will be required during installation, operation, maintenance and in an
emergency?
 Will workers be able to have safe access without injury from the plant itself or the risk of
slips, trips and falls (walkway, gantry, elevated work platform, fixed ladders)?
Location
 How would the plant affect the safety of the area where it will be located (e.g. its impact on
design and layout of the workplace)?
 How would the location affect the safety of the plant (e.g. environmental conditions, terrain
and work area)?
 Are there likely to be other people or other plant in the vicinity? What effect would this
have?
Systems of work
 What systems of work would be associated with the plant? Could they create any
hazards?
 Would the plant’s safety depend on the competency of its operators?
 What kind of training, information, instruction and supervision is needed for workers and
other persons who may need to operate or be near the plant?
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Abnormal situations
 What abnormal situations, misuse or fluctuation in operating conditions can you foresee?
 What effects would failure of the plant have? Would it result in loss of contents, loss of
load, unintended ejection of work pieces, explosion, fragmentation, collapse of parts?
 Would it be possible for the plant to move or be operated inadvertently?
2.2 Assessing the risks
A risk assessment involves considering what could happen if someone is exposed to a hazard
and the likelihood of it happening.
A risk assessment can be undertaken with varying degrees of detail, depending on the complexity
of the plant and the type of information available, and may involve specific risk analysis tools and
techniques.
A risk assessment is unnecessary if you already know the risk and how to control it.
To assess the risk associated with plant hazards you have identified, you should consider the
following:
 how often and for how long people would be exposed to each of the potentially hazardous
situations you have identified (this affects likelihood as the longer and the more frequent
the exposure to a potential hazard, the more likely it is to cause harm)
 how many people would be exposed to the potential hazard at the same time (this affects
the consequence)
 both technical and human factors, including a person’s ability to change behaviour to
compensate for design changes.
2.3 Controlling the risks
The ways of controlling risks are ranked from the highest level of protection and reliability to the
lowest. This ranking is known as the hierarchy of risk control. The WHS Regulations require duty
holders to work through this hierarchy to choose the control that most effectively eliminates, or
where that is not reasonably practicable, minimises the risk in the circumstances. Specific controls
are required under the WHS Regulations for certain types of plant, such as:
 powered mobile plant
 plant that lifts or suspends loads
 industrial robots
 lasers
 pressure equipment
 scaffolds.
Elimination – The most effective control measure is to remove the hazard or hazardous work
practice associated with the plant. Many hazards can be addressed at the design, manufacture,
supply and installation stages. For example, designing machinery to produce low noise levels is
more effective than having to provide workers with personal hearing protection. This also avoids
costly modifications to plant after it is purchased.
If elimination is not reasonably practicable, you must minimise the risk by:
 Substitution – substitute the plant (or hazardous parts of it) with plant that is safer. For
example, a manufacturer may be able to substitute a component with one that has higher
heat tolerance.
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

Isolation – separate the hazardous plant from people, either by distance or physical
barrier. For example plant could be specified for use in an isolated or controlled
environment.
Engineering controls – include modifications to tools or equipment, for example an
importer could install guards to prevent contact with moving parts of machinery or retrofit a
roll over protective structure on a tractor.
If risk remains, it must be minimised by implementing administrative controls, so far as is
reasonably practicable, for example using a lock-out system of work to ensure that plant can be
physically isolated from its power source while maintenance or cleaning work is being done.
Providing training and supervision, using warning signs or arranging work to minimise the time
spent near noisy machinery are all examples of administrative controls.
Any remaining risk must be minimised with suitable personal protective equipment (PPE), such as
providing workers with breathing protection, hard hats, gloves, aprons and protective eyewear.
Administrative control measures and PPE rely on human behaviour and supervision, and used on
their own, tend to be least effective in minimising risks.
Combinations of control measures
In many cases, a combination of control measures will provide the best solution. For example,
protecting workers from flying debris when using a concrete cutting saw may involve guarding the
blade (engineering), isolating the work area by using barriers (isolation) and signs
(administrative), and providing PPE such as a face shield.
2.4 Reviewing risk control measures
The control measures that are implemented must be reviewed, and if necessary, revised to make
sure they work as planned and that no new hazards have been introduced by the control
measures.
A person conducting a business or undertaking must review and as necessary revise control
measures:
 when the control measure is not effective in controlling the risk
 before a change at the workplace that is likely to give rise to a new or different health and
safety risk that the control measure may not effectively control
 if a new hazard or risk is identified
 if the results of consultation indicate that a review is necessary
 if a health and safety representative requests a review.
Designers, manufacturers, importers and suppliers of plant may use quality assurance processes
to check that the plant effectively minimises health and safety risks. Obtain feedback from users
of the plant to determine whether any improvements can be made to make it safer.
2.5
Information sources
There are a range of sources that may assist in managing risks associated with the plant and the
systems of work used in connection with the plant.
Researching information
 WHS legislation, codes of practice and technical standards covering design, manufacture,
testing and use of plant
 Injury, faults, incident and accident reports, and plant failure data kept by manufacturers
and users of the same or similar types of plant
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


Statistics, hazard alerts or other reports from relevant statutory authorities, unions and
employer associations, specialists, professional bodies representing designers,
manufacturers, or engineers
Information and documentation supplied by designers or manufacturers on safety and
health issues, such as test reports on previous designs or similar plant
Relevant reports or articles from occupational health and safety journals, technical
references or data bases.
Inspection and testing
 Inspect plant that has failed and been returned by users
 Develop prototypes, and inspect and test their design and manufacture
 Conduct ‘walk-through’ surveys of the workplace where the plant will be used before
beginning the design process and while the plant is being installed or erected (the latter to
look for hazards which may be introduced during installation).
Consultation
Where possible, talk to other designers, manufacturers, installers and users. People actually
working with the same or similar plant are often well aware of what can go wrong and why, and
how the work environment can change. It also enables any issues to be discussed, for example
the practicality of substituting materials in the manufacturing process.
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3
3.1
SAFE DESIGN OF PLANT
What is safe design?
Safe design means the integration of control measures early in the design process to eliminate or,
if this is not reasonable practicable, minimise risks to health and safety throughout the life of the
plant being designed.
The safe design of any type of plant will always be part of a wider set of design objectives,
including practicability, aesthetics, cost and functionality. These sometimes competing objectives
need to be balanced in a manner that does not compromise the health and safety of those
potentially affected by the plant over its life.
Safe design begins at the concept development phase when choices are made about design,
materials used and methods of manufacture. Safer plant will be created when hazards and risks
that could impact on downstream users over the lifecycle are eliminated or minimised during
design and before manufacture. In these early phases there is greater scope to design-out
hazards or incorporate risk control measures that are compatible with the original design concept
and functional requirements of the product.
3.2
The role of designers
A designer is a person conducting a business or undertaking whose profession, trade or business
involves them in:
 preparing sketches, plans or drawings for plant that is to be used or could reasonably be
expected to be used at a workplace, including variations to a plan or changes to the plant
 making decisions for incorporation into a design that may affect the health or safety of
persons who manufacture, use or carry out other activities in relation to the plant.
Designers include design professionals such as engineers, industrial designers and designers of
plant systems such as software and electrical systems.
A person will also have the duties of a designer if they alter the design during manufacture, or
alter existing plant, so that new measures for controlling risk are required. For example, if the
maximum working radius of a mobile crane is increased by fitting a longer boom, a new load chart
needs to be prepared to control the increased risk of the crane overturning. The person designing
the boom extension should contact the original designer to ensure the new boom extension does
not compromise the existing design criteria or safety factors.
Consider the lifecycle
Safe design applies to every stage in the lifecycle, from conception through to disposal.
The WHS Act requires the designer to ensure, so far as is reasonably practicable, that the plant is
designed to be without risks to the health and safety of persons who:
 use the plant for a purpose for which it was designed
 store the plant at a workplace
 carry out any reasonably foreseeable activity at a workplace in relation the manufacture,
assembly, use, storage, decommissioning, dismantling or disposal of the plant, or
 are at or in the vicinity of a workplace and are exposed to the plant or whose health and
safety may be affected by an activity related to the plant.
This means thinking about potential hazards and design solutions as the plant is manufactured,
transported, installed, commissioned, operated, maintained, repaired, de-commissioned,
dismantled and disposed of or recycled
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Knowledge and capability
In addition to core design capabilities, the following skills and knowledge should be demonstrated
or acquired by a designer:
 knowledge of work health and safety legislation, codes of practice and other regulatory
requirements
 understanding the intended use of the plant throughout its lifecycle
 knowledge of hazard identification, risk assessment and control methods
 knowledge of technical design standards, and
 the ability to source and apply relevant data on human dimensions, capacities and
behaviours.
Many design projects are too large and complex to be fully understood by one person. Various
persons with specific skills and expertise may need to be included in the design team or consulted
during the design process to fill any knowledge gaps, for example ergonomists, engineers and
occupational hygienists.
3.3
Integrating safe design and risk management
The design brief should include a requirement to apply a risk management process in the design.
The safe design of plant is usually an iterative process. After the initial control measures are
incorporated into the design, the design is reviewed to determine whether there are remaining
risks and whether redesign can eliminate or minimise these risks (see Figure 1).
3.4
Pre-design and concept development phase
This stage of the process involves:




Establishing the design context in terms of the purpose of the plant, its functions and
limitations
Identifying the roles and responsibilities of various parties in relation to the project, and
establishing collaborative relationships with clients, manufacturers and users of the plant
Conducting research and consultation to assist in identifying hazards, assessing and
controlling risks (see section 2.5)
Conducting hazard identification
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Conduct research and
consultation
Establish the design
context
Pre-design phase
Obtain information including:
• Purpose of the plant, its
functions and limitations
• Data from similar types of
plant, test reports
• WHS legislation, codes of
practice, technical standards.
Identify hazards associated with the plant
Develop prototype or initial design
Determine how hazards will be eliminated or
minimised through either:
(a) implementing solutions from recognised
technical Standards; or
(b) conducting a risk management process.
(a) Implement solutions from
recognised Standards.
Identify hazards that can be
adequately addressed by applying
solutions/guidance from existing
standards if appropriate
Conceptual and schematic
design phase
Hazard identification (technical
and human factors):
• Hazardous conditions
• High consequence hazards
• Systems of work
• Plant access and location
• Abnormal situations.
Design development phase
(b) Conduct a risk assessment process
for hazards which have no suitable
solutions in recognised Standards or
there is poor safety experience with
this type of hazard.
Design risk controls
Test, trial or evaluate the design
Determine information needs
for safety during the lifecycle
Final design
Yes
SS
Have risks been eliminated or
minimised so far as is
reasonably practicable?
Redesign to
reduce risks
within the
designers control.
NO
Figure 1: A systematic approach to integrating design and risk management
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Plant functions and limitations
Identify the functions of the plant and its limitations, for example:








the specifications (what is produced, materials to be used)
expected place of use (environment, supporting surface)
planned service life
intended functions and operating modes
expected malfunctions and faults
the people interacting with the plant
the products related to the plant
the correct use of the plant, as well as reasonably foreseeable misuse.
Plant limitations
Use limits
Space limits
Time limits
Environmental limits
Interface limits
Examples
Intended use, production rates, cycle times, working
load limits
Range of movement, access for maintenance
Wear and tear of materials, use of fluids
Temperature, humidity, noise, location
Other plant, energy sources
Hazard identification
Hazard identification should take place as early as possible in the concept development and
design stages. It involves identifying the various activities that the plant would be subjected to
throughout its life and the reasonably foreseeable hazards associated with each activity.
Hazards may include but are not
limited to the following……..
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3.5
Mechanical (crushing, cutting,
trapping, shearing)
Electrical
Thermal
Noise
Vibration
Radiation
Hazardous chemicals
Slipping, tripping and falling
Manual handling
Confined spaces
Environmental conditions
Hazards resulting from a
combination of the above
…..in all phases of the plant lifecycle
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manufacture
storage
packing and transportation
unloading and unpacking
assembly
installation
commissioning
use
cleaning
adjustment
inspection
planned and unplanned
maintenance
repair
decommissioning
dismantling
disposal
recycling.
Design phase
The design phase may involve:
 developing a prototype or initial design
 testing, trialling or evaluating the prototype or design
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redesigning to control any remaining risks so far as is reasonably practicable
finalising the design and prepare risk control plans for the lifecycle of the product.
Some hazards may be adequately addressed by applying existing solutions in published technical
standards. Alternatively, a risk management process should be used to develop and select the
most effective control measure.
Technical standards
Plant should be designed by a competent person (for example, a qualified engineer) in
accordance with acceptable engineering principles and relevant technical standards. Engineering
principles include, for example, mathematical or scientific procedures outlined in an engineering
reference or standard.
A list of some relevant published technical standards is included at Appendix A. The list is not
exhaustive and designers may consider using other technical standards when designing plant.
3.6 Testing and examination of plant
Designers must carry out, or arrange the carrying out of, any calculations, analysis, testing or
examination that may be necessary to ensure, so far is reasonably practicable, that the plant is
designed to be without risks to health and safety.
Analysis, testing or examination can be carried out when developing a prototype and during the
manufacturing stage. Designers should require that consideration should be given to:
 simulation of the normal range of operational capabilities
 testing of design features incorporated to ensure ‘fail-safe’ operation
 measurement of imposed stresses on critical components to ensure maximum design
stresses are not exceeded
 testing of critical safety features such as overspeed and over-pressure devices under both
normal and adverse operational conditions
 development of overload testing procedures to ensure plant safety during foreseeable
misuse conditions.
Records of tests and examinations should be maintained and provided to the manufacturer of the
plant.
3.7
Providing information
Designers must give adequate information to each person who is provided with the design in
order to give effect to it concerning:
 the purpose for which the plant was designed
 the results of any calculations, testing, analysis or examination
 any conditions necessary to ensure that the plant is without risks when used for a purpose
for which it was designed or when carrying out any activity related to the plant.
The designer must also, so far as is reasonably practicable, provide this information to any person
who carries out activities in relation to the plant.
For example, if plant is to be located a specific distance from other plant, written instructions must
be provided for the manufacturer, supplier, installer, owner and end user.
If the manufacturer advises the designer that there are safety issues with the design, the designer
must revise the information to take account of these concerns, or tell the manufacturer in writing
the reasons why such revision is not necessary.
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Information provided to the manufacturer (or supplier if you are also manufacturing the plant)
should include details of any risks you have not been able to eliminate.
Information should be provided in a manner that can be clearly understood by persons who may
use the plant and may be a combination of written text or visual information such as signs,
symbols or diagrams. Where visual information is provided, it should conform to the relevant
standard.
Type of information to provide
Under the WHS Regulations, designers must provide specific information to the manufacturer to
enable the plant to be manufactured in accordance with the design specifications. If relevant,
information must be provided on:
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the installation, commissioning, use, handling, storage, decommissioning and dismantling
of the plant
hazards associated with use of the plant
testing or inspections required for the plant or structure
systems of work and competency of operators required for the safe use
emergency procedures if there is a malfunction.
Examples of information that may be needed include:
Manufacture of plant
For example:
 any specific conditions relating to the method of manufacture
 instruction to the manufacturer for fitting or refitting plant parts and their location on the
larger components of the plant or their housings where:
o the direction of movement should be known in order to avoid a risk
o associated errors which could be made in installation
o instruction where hot or cold parts or material may create a hazard.
In the case of registrable plant design, the information provided by the designer to the
manufacturer should include the plant design registration number in order to provide evidence that
the plant design has been registered in accordance with the WHS Regulations.
Transport, handling and storage of plant
For example:
 dimensions and weight
 indications for handling, for example, application points for lifting equipment
 conditions for storage.
Installation and commissioning
For example:
 exposure of dangerous parts prior to the fixing of guarding
 lifting procedures
 stability during installation
 the proposed method for installation and commissioning, including tests that should be
carried out
 the use of special tools, jigs and appliances necessary to minimise any risk of injury during
installation
 the interaction of plant with other plant
 environmental factors affecting installation and commissioning.
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Using, inspecting and testing plant
For example:
 the comprehensive range of uses for which the plant is intended, including prohibited
usages
 requirements for maintenance and repair, such as nature and frequency of maintenance,
disposal of hazardous by-product and consumables
 emergency situations, for example, types of fire fighting equipment
 exposure to hazardous substances
 effects of environmental conditions on the use of the plant
 the results or documentation of tests and examinations carried out on the plant and design
 de-commissioning, dismantling and disposal of plant
 any known residual risks, that is, those that cannot be eliminated or sufficiently reduced by
design and against which guarding is not totally effective
 the control measures, for example, personal protective equipment, that should be used to
further reduce the risks associated with plant
 guidance, if required, on administrative controls
 requirements for special tools needed to use or maintain plant.
Details of critical components1 should be documented so that the specifications, applicable
standards to which they comply and source of evidence that demonstrates compliance (i.e. test
report, third party certificates) is readily available. In maintenance and repair, critical components
should only be replaced by equivalents.
3.8
Registering plant design
Schedule 5 of the WHS Regulations requires certain plant designs and items of plant to be
registered (registrable plant). Schedule 5 is reproduced in Appendix B.
Plant design registration involves registering a design from which any number of individual items
can be manufactured to that same design.
How to register a plant design
In order to register a plant design, the design must be verified by a design verifier who must
provide a statement that the design has been produced in accordance with published technical
standards or engineering principles.
Any drawings or other documents provided with the application must be capable of being kept in
an electronic form.
Design verification
The design verification statement is prepared by a design verifier stating that the design has been
checked for design integrity and that the design has been produced in accordance with the
referenced technical standards and engineering principles. It must be in writing and signed by the
design verifier. The statement must include the name and address details of the verifier and
business or employment details.
Design verifier
R. 253: A design verifier must document the verification process carried out by that person and
the results of that process.
‘critical components’. These are components or sub-assemblies – the failure of which will leave the plant in a
condition that exposes operators or others to an unacceptable risk level.
1
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A design can only be verified by a person who is eligible to be a design verifier under the WHS
Regulations. The types of people who would be competent to verify the design of plant may
include someone who:
 has educational or vocational qualifications in an engineering discipline relevant to the
design to be verified
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has knowledge of the technical standards relevant to the design to be verified
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has the skills necessary to independently verify that the design was produced in
accordance with the published technical standards and engineering principles used in the
design
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is certified by a body that is accredited or approved by the Joint Accreditation System—
Australia and New Zealand or an equivalent overseas body to undertake conformity
assessments of the design against the relevant technical standards.
For example, this could include someone who is registered on the National Professional
Engineers Register administered by the Institution of Engineers Australia and is determined by
that Institution to be competent to design the structure, verify the design or inspect the plant or
structure (as the case requires), or is a member of the Institution of Engineers Australia with the
status of Chartered Professional Engineer.
The design verifier must not have been involved in the plant design process. The design verifier
cannot have been engaged by the same organisation that produced the design unless the
organisation has a quality system in place that has been certified by a body accredited or
approved by the Joint Accreditation system of Australia and New Zealand (JASANZ).
Once the design is registered
When a plant design is registered, the WHS regulator will issue a plant design registration
document that will contain the registration number for the plant design and the date of effect on
which the registration takes place. This document must be kept and made available for any
inspection required under the WHS Act.
If it is lost, stolen or destroyed, then you will need to apply to the WHS regulator that registered
the plant for a replacement document as soon as possible outlining the reasons for needing a
replacement.
The WHS regulator may impose any conditions it considers appropriate on the registration of the
plant design, including conditions in relation to record keeping or provision of information to the
WHS regulator.
The registration number must be given to the manufacturer, importer or supplier of plant. These
duty holders must ensure that the design registration number is provided to the person with
management or control of the plant at a workplace.
Changes to design registration
If the design of a registered plant is altered so as to require any new risk control measures, the
altered design must be registered.
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4
4.1
DESIGN CONSIDERATIONS
Physical characteristics of users
Plant should be designed to accommodate the range of physical characteristics in the user
population. You should take into account information about the range of human dimensions and
capabilities, for example height, reach and weight, to provide an optimum match between plant
and users.
Designers should take into consideration the smaller stature of some cultural groups.
A designer should apply ergonomic design principles so that when the plant is being used
properly, the operator’s discomfort, fatigue and psychological stress are minimised as much as
practicable.
Further information on the consideration of the human body and the design of plant is available in
AS 4024.1701 Human body measurements – Basic human body measurements for technological
design.
4.2
Design to facilitate safe use
A designer should address the following issues:
 the required skill levels to operate or maintain the plant
 the complexity of functions an operator can be expected to perform
 the need for and the location of items such as aids, guides, indicators, guards, mounted
instruction, signs, symbols and name plates, which may be useful to facilitate correct
actions and prevent operator errors
 ensuring plant design is fail safe at least to the level of reliability/safety integrity level as
determined by the plant risk assessment
 layout of the work stations, for example, the position of the worker in relation to plant
controls
 instrumentation required at each work station or cabin, and the layout of this
instrumentation
 the specific devices, tools or controls the operator and support people will need to perform
their jobs safely
 the options available to enable quick recovery or to maintain the safety and integrity of the
system in the event of operator error or plant failure and the means available to access the
operator in the event that assistance is required
 environmental conditions that will tend to impair operator performance, for example, long
periods where the operator engages in physical or repetitive activity or inactivity in a hot or
cold environment
 separation of persons, including the operator, from entrapment as a result of plant
operation i.e. being caught between the plant and other objects in operation.
You should also take into account predictable human behaviour and never presume those who
use or maintain plant have a full or continuous appreciation of essential safety features. Where
there is a likelihood of operator error, higher order control measures should be incorporated into
the design.
For example:
A driver used a tractor to haul a hydraulically operated tilt-up trailer loaded with grain. The
gear lever of the tractor was positioned close to the control lever which operated the tip-up
mechanism of the trailer. While underway, the driver’s arm moved the control lever slightly
so the trailer tray began to lift. The trailer rose and eventually overturned.
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4.3
Reasonably foreseeable misuse
Sometimes plant may be used for applications other than those for which it was designed and
originally intended, for example where an excavator is used to lift and transport concrete pipes.
When designing plant the risk of reasonably foreseeable misuse should be assessed and
appropriate control measures incorporated in the design.
4.4
Minimising human error
Human or worker error is not always the result of carelessness or negligence. The desire for extra
speed, increased production and making tasks easier are some of the main reasons why guards
are bypassed or removed. Workers may also use unsafe practices to overcome poor plant design
or become bored and distracted with repetitious work, which may cause loss of concentration. In
designing plant, designers should be aware of the factors contributing to human error, including:
 forgetfulness
 workers’ diligence to ‘get the job done’ or to ‘find a better way’
 capacity to understand information
 ergonomics
 psychological or cultural environment
 habit
 fatigue
 level of training.
Further information on human error is included in Appendix C.
4.5
Environmental conditions
A designer should consider the hazards created by the range of physical, environmental and
operational conditions to which plant will be exposed during its life. For example, where moving
parts may be exposed to dust which could cause the plant to malfunction, a designer should
incorporate effective dust covers into the design. The same is true for extreme heat or cold. A
designer should ensure that these hazards are minimised or guarded against. This may require
the designer to provide instructions to erectors and installers of plant about the precise positioning
of the installation.
If an operator is physically uncomfortable in operating the plant this may lead to such problems as
inattention, carelessness or fatigue which may in turn result in injury or death. For example a
poorly designed workstation or cabin where layout design is not based on ergonomic principles
can lead to the problems outlined above.
4.6
Erection and installation
A designer should recognise that hazards associated with the erection and installation of plant are
identified and eliminated or minimised. For example, poor access to fasteners such as clips and
bolt holes may mean that an erector or installer needs to stretch or bend at an unnatural angle.
This might result in musculoskeletal injury to the erector or installer.
Designers should also design plant so it can be erected or installed safely, for example, so that it
will have adequate stability and special supports if these are required, especially if a partly
completed structure may be unstable, or be designed into sub-assemblies so that each is more
manoeuvrable than if it were a complete assembly.
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4.7
Maintenance
If the need to operate plant during maintenance or cleaning cannot be eliminated, the
designer must ensure that the design provides for operator controls that:
 Permit the operation of plant during maintenance or cleaning,
 Cannot be operated by any other person than the person carrying out
maintenance
 Will allow operation of the plant in such a way that any risk with maintenance
and cleaning is eliminated or minimised, so far as reasonably practicable.
A designer’s responsibility extends to ensuring that maintenance on plant can be undertaken
safely. Any reasonably foreseeable hazards with future plant maintenance and repair should be
identified and designed out so far as is reasonably practicable.
Where a worker is required to maintain operating plant, a designer should ensure:
 locations for undertaking adjustment, lubrication and maintenance are consciously
designed to be outside danger zones. This may be achieved, for example, by placing
clearly labelled lubrication points away from moving parts
 where locations for undertaking maintenance cannot be placed outside danger zones, the
design should incorporate interlocks to ensure the plant cannot be activated while work is
carried out in these zones
 safe access, for example walkways and guardrails need to be provided to enable safe
maintenance and inspection of plant such as cooling towers or storage silos
 all relevant information is passed on to the manufacturer for inclusion in the
manufacturer’s instructions for maintenance
 parts of the plant where workers move or stand are designed to prevent injuries arising
from slips, trips and falls, and
 the design eliminates or minimises the risk of inadvertently touching or coming into contact
with hot or moving parts.
4.8
Guarding
A guard is a physical or other barrier that can perform several functions, including:
 preventing contact with moving parts or controlling access to dangerous areas of plant
 screening harmful emissions such as radiation
 minimising noise through the application of sound-absorbing materials
 preventing ejected parts or off-cuts from striking people.
Guards may include (see Figure 2):
 Permanently fixed or interlocked physical barriers
 Self-adjusting guards
 Presence-sensing systems
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Figure 2: Examples of guards on a press brake.
If guarding is used, the designer must ensure that:
 the guarding will prevent access to the danger point or danger area of the plant
 if access to the area of plant requiring guarding is not necessary during operation,
maintenance or cleaning, the guarding is a permanently fixed barrier,
 if access to the areas requiring guarding is necessary during operation,
maintenance or cleaning, the guarding is an interlocked physical barrier,
 if it is not reasonably practicable to use a permanently fixed barrier or an interlocked
physical barrier, the guarding is a physical barrier that can be altered or removed
using a tool, or
 if it is not reasonably practicable to use a permanently fixed barrier, an interlocked
physical barrier or a physical barrier fixed in position, the guarding includes a
presence-sensing safeguarding system.
Guarding must:
 be of solid construction and securely mounted so as to resist impact or shock
 make by-passing or disabling of the guard as difficult as reasonably practicable
 not create a risk in itself (for example it must not obstruct operator visibility, weaken
the plant, cause discomfort to operators or introduce new hazards such as pinch
points, rough or sharp edges)
 control any risk from potential broken or ejected parts and workpieces
 allow for servicing, maintenance and repair to be undertaken with relative ease, and
 if guarding is removed the plant cannot be restarted unless the guarding is
replaced.
Guard design
The mechanisms and controls forming part of a machine guard should be of a fail-safe design.
Guards must not in themselves create hazards. For example, the guarding should not weaken the
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structure of the plant, cause discomfort to the people using the plant or introduce new hazards
such as pinch points, rough edges or sharp corners.
Where some form of physical barrier is provided to prevent access to dangerous parts, the size
and position of the barrier should take into account the range in height and build of people using
the plant.
The design of the guard should be for a specific function, with design consideration being given,
where appropriate, to:
 the placement
 removal or ejection of work pieces
 lubrication
 inspection
 adjustment
 repair of machine parts.
Guarding should be designed for safe operation of the plant as well as to minimise interference to
the plant.
The selection of a guard should take into consideration the environment in which it is to be used.
Some examples of poor guard selection relative to the environment are: electrical charging of
guards on high frequency welders; heating of guards in hot processes; and wire mesh guards on
machines emitting splashes.
Physical barrier guarding should be constructed of material that is strong enough to resist normal
wear and shock that may arise from failure of the parts or processes being guarded; and to
withstand long use with a minimum of maintenance. If a guard is likely to be exposed to corrosion,
corrosion-resistant materials or surface coatings should be used.
When an enclosure is used to prevent access to mechanical, chemical and electrical hazards,
there may be an opportunity to control other risks. For example, risk associated with exposure to
dust may be controlled by substituting a sheet metal guard for a mesh one provided the
accumulation of dust within the guard does not constitute an additional hazard.
Where there is a risk of jamming or blockage of moving parts, the designer should ensure that
specific work procedures, devices and tools that will enable the plant to be cleared in a way that
reduces the risk are documented.
If applicable, the designer should ensure that safe systems of work associated with the use and
maintenance of the guarding and the maintenance of the components being guarded, are
specified in the information provided to the manufacturer.
4.9
Operator control devices
A designer of plant must ensure that the design provides for any operator controls to be:
 identified so as to indicate their nature, function and direction of operation
 located so they can be readily and conveniently operated
 located or guarded to prevent unintentional activation, and
 locked into the “off” position to enable disconnection from power.
Badly designed operator controls can lead to unintentional unsafe operation. For example, a
control for setting the speed for a cutting device such as a saw or guillotine should not be a simple
slider or rotary control. It should be graduated in fixed lockable steps.
Control devices should be designed:
 to enable the plant to fail to a safe condition
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to be within easy access of the operator
to enable extra emergency stops to be located so they can be operated from other parts of
the plant. A risk assessment would assist in their location
so they are clearly visible, identifiable and appropriately marked where necessary, for
example, signed to indicate on/off
so the intended function of the control is clearly indicated and the action used to operate
the control is aligned with the effect on the plant – for example, moving a control to the
right should move the plant to the right
using symbols as opposed to written instructions, wherever possible,
so they can be easily read and understood, especially in the case of dials and gauges
so the movement of the control is consistent with established convention, for example,
anticlockwise to open, clockwise to close
so the desired effect can only occur by intentional operation of a control, for example,
provision of a starting control
to withstand the rigours of normal use, undue forces and environmental conditions
so they are located outside danger zones
so they are located or guarded to prevent unintentional activation
so they can be locked in the ‘off’ position to enable disconnection of power
so they are readily accessible for maintenance.
It should only be possible to start plant by deliberately actioning a control provided for that
purpose. The same requirement applies when restarting the plant after any stoppage. Each item
of plant should be designed to accommodate a control so the plant or its relevant components can
be brought to a complete stop safely.
Further information on controls and symbols is available in AS 4024: Safeguarding of machinery –
general principles.
4.10 Emergency stops
A designer of plant must ensure that if the plant is to be operated or attended by more than
one person and more than one emergency stop control is fitted, the design must provide
for multiple emergency stop controls to be of the “stop and lock-off” type, so that the plant
cannot be restarted after an emergency stop control has been used unless that emergency
stop control is reset.
If the design of the plant includes emergency stop controls, the designer must ensure that
the design provides:
 for the stop control to be prominent, clearly and durably marked and immediately
accessible to each operator of the plant , for example ‘EMERGENCY STOP –
PRESS’
 for any handle, bar or push button associated with the stop control to be coloured
red, and
 that the stop control cannot be adversely affected by electrical or electronic circuit
malfunction.
Emergency stop devices should not be the only method of controlling risks. They should be
designed as a backup to other control measures.
The emergency stop system should be compatible with the operational characteristics of plant.
Emergency stops do not remove the need for adequate guarding.
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Once engaged, the emergency stop controls should remain that way. It should be possible to
disengage the emergency stop controls only by a deliberate action. Disengaging the emergency
stop control should not restart the plant. It should only permit the normal starting sequence to be
activated.
In the case of plant or parts of plant designed to work together, stop controls (including the
emergency stop) should be capable of stopping the plant itself as well as all the equipment
interrelated to its operation, where continued operation of this interrelated equipment may be
dangerous.
4.11 Failure of the control circuit
A control circuit used to control the plant should be designed in such a way as to prevent a fault in
the control circuit logic, or a failure of or damage to the control circuit leading to the operator or
others being placed at risk. In particular:
 the plant must not start unexpectedly
 the plant must not be prevented from stopping if such a command has already been given
 no moving part of the plant or workpiece being held by the plant must fall or be ejected
 automatic or manual stopping of moving parts must not be impeded
 the protection device/s must remain fully effective.
4.12 Warning devices
If it is necessary to include an emergency warning device to minimise risk, the designer of
plant must ensure that the design provides for the device to be positioned on the plant so
that it will work to best effect.
Warning devices include:
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Audible alarms
Motion sensors
Lights
Rotary flashing lights
Air horns
Percussion alarms
Radio sensing devices
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5
5.1
MANUFACTURE OF PLANT
The role of manufacturers
S. 23: Manufacturers must ensure, so far is reasonably practicable, that the plant is manufactured
to be without risks to the health and safety of persons who assemble or use the plant for a
purpose for which it was designed or manufactured, or store, decommission, dismantle or dispose
of the plant.
The manufacturer must use the design specifications provided by the designer. If the
manufacturer identifies a hazard in the design for which the designer did not provide a control
measure, the manufacturer must:
 not incorporate that hazard into the item of plant during manufacture
 give the designer written notice of the hazard as soon as practicable
 take all reasonable steps to consult with the designer of the plant in relation to alteration of
the design to rectify the hazard.
Consultation between manufacturer and designer will facilitate the discharge of each other’s
obligations and any manufacturing issues to be discussed, e.g. practicalities of materials
substitution in the manufacturing process.
Where it is not possible for the manufacturer to advise the designer of an identified hazard and
associated risk in relation to the design, the manufacturer must ensure the risk is eliminated or
minimised so far as is practicable.
If a manufacturer or any other person modifies the design of plant without consulting the original
designer, that person will have the duties of a designer. All modifications should be approved by
the original designer or by a competent person, for example, substitution of metals in a
manufacturing process should be approved by the original designer or a person with relevant
expertise before the substitute material is incorporated.
The manufacturer must ensure the plant is supplied with appropriate information on safe use.
5.2
Plant construction
The manufacturer must ensure that the plant is manufactured, inspected and, if required, tested in
accordance with the designer’s specifications.
Connected, fabricated or machined materials are likely to be required in the construction of plant.
Manufacturing processes require that design specifications are followed, for example, crane
booms of a particular lifting capacity should have the particular grade of steel specified. Further
the grade of steel used in the manufacture must be clearly identified in information provided with
the finished product.
The manufacturer may choose to consider other published technical standards for guidance on
the materials used for the plant, the method of construction and testing to achieve safety of the
plant.
Guarding
A manufacturer of plant must ensure that guarding used as a control measure is of solid
construction and securely mounted so as to resist impact or shock. Guarding must be of a kind
that can be removed to allow for maintenance and cleaning of the plant at any time it is not in
normal operation. The manufacturer must ensure, so far as is reasonably practicable, that if the
guarding were to be removed, the plant cannot be restarted until the guarding is replaced.
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The selection of material from which guards can be constructed is determined by four main
considerations, which are:
 strength and durability, for example use of non-metallic materials in corrosive
environments
 effects on machine reliability, for example a solid guard may cause the machine to
overheat while a mesh guard may allow dust into the working environment
 visibility, for example there may be operational and safety reasons for needing a clear
view of the danger area
 the control of other hazards, for example the use of a material that will not permit the
ejection of molten metal.
5.3 Testing and examination of plant
S. 23: Manufacturers must carry out, or arrange the carrying out of, any calculations, analysis,
testing or examination that may be necessary to ensure, so far is reasonably practicable, that the
plant is manufactured to be without risks to health and safety.
Details of the testing and examination carried out should be documented and must be provided to
the each person to whom the manufacturer provides the plant. Typical testing nominated by the
designer may include but will not be limited to:
 electrical testing (e.g. input current, safety contactor current, leakage current, protective
earth continuity, dielectric strength test, and insulation resistance)
 safety function testing (e.g. safety circuit operation times, appropriate installation
distances, use of appropriate components and reliability design)
 temperature rise tests (e.g. for exposed temperature hazards and to confirm components
are used within their specification)
 pressure, stability, mechanical or structural testing to the levels required by the design
specification
 abnormal condition tests (e.g. foreseeable component failures, unexpected start up,
hazards following interruption, restoration of power sources – electricity, air - as decided
by the risk assessment process.
Tests and examinations should include:
 all critical components
 the suitability of selected components
 mechanical devices
 pneumatic devices
 hydraulic devices
 sources of emissions e.g. lasers
 guarding and interlocking arrangements
 structural integrity
 material types and properties.
There are both visual and non-visual techniques for checking the integrity of plant manufacture.
For example, checking welded joints requires non-visual, non-destructive testing (NDT)
techniques.
For all high risk plant where welding is used as a joining technique, NDT techniques such as
ultrasonic and x-ray procedures should be used to ensure the welds are defect free and fit for the
intended purpose. Consideration should also be given to structural flexure and the avoidance of
tri-axial stressing as a measure of reducing the tendency towards fatigue cracking.
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To ensure an accurate assessment of operational stresses is made consideration should be given
to the use of techniques such as strain gauging and/or photo-elastic techniques. Stresses should
be measured dynamically under a range of operational conditions.
5.4 Information about the safe use of plant
Manufacturers must give adequate information to each person who is provided with the plant
concerning:
 the purpose for which the plant was designed or manufactured
 the results of any calculations, testing, analysis or examination
 any conditions necessary to ensure that the plant is without risks when used for a purpose
for which it was designed or manufactured or when carrying out any activity related to the
plant.
A manufacturer must take all reasonable steps to obtain the information from the designer of the
plant and pass it on to the person to whom the manufacturer supplies the plant. See section 3.7
for the type of information that should be provided.
Instructions should be trialled to ensure the intent of the instructions is achieved and that carrying
out the instructions does not pose a risk to health and safety. Information may be provided in the
form of written text or visual information such as signs, symbols or diagrams.
5.5 Registration of plant design
Certain plant requires design registration as outlined in Appendix B. If the designer has registered
the design, the designer must provide the design registration number to the manufacturer. The
manufacturer must ensure that they pass on the design registration number to the person being
supplied with the plant manufactured to the design.
R. 231: A manufacturer must not supply plant that requires design registration unless the design
of that plant has been registered.
If the designer has not registered the plant design, then the manufacturer must register the plant
design. If the manufacturing process has involved modifying an already registered plant design in
such a way that it requires new risk control measures, the altered design must be registered.
5.6 Item registration
Any plant that requires item registration (see Appendix B) must be registered with the WHS
regulator. A manufacturer who produces a number of the same items of plant may apply for the
item registration, noting that once it is sold to someone else, the manufacturer must notify the
WHS regulator that they no longer have management of control of that item of plant.
Marking of registered items of plant
In the case of plant that requires item registration, the item registration number provided by the
WHS regulator must be permanently marked on the plant in a location that will be readily
accessible. It will generally be a simple task to mark large items of plant with the item registration
number by either etching the number in place or by fixing the number in place in a position that
will not lead to damage or removal over time
On some items, such as a tower crane that may comprise many parts and is often assembled in a
configuration to suit a particular workplace/task, it may not be feasible to mark each component.
In such cases, the item registration number should be marked on those components that are
readily accessible and able to be seen when the crane is fully assembled.
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6
IMPORT AND SUPPLY OF PLANT
Importers and suppliers must ensure, so far is reasonably practicable, that the plant is without
risks to the health and safety of persons who assemble or use the plant for a purpose for which it
was designed or manufactured, or store, decommission, dismantle or dispose of the plant.
Importers and suppliers must, so far as is reasonably practicable, eliminate or minimise risks to
health and safety with regard to the plant being supplied, where the manufacturer has not already
done so. This may be necessary where the importer has no direct connection to an overseas
designer or manufacturer.
6.1 Examination and testing of plant
Importers and suppliers must carry out, or arrange the carrying out of, any calculations, analysis,
testing or examination that may be necessary to ensure, so far is reasonably practicable, that the
plant is without risks to health and safety.
Alternatively, they must ensure the calculations, analysis, testing or examination has been carried
out.
Importers or suppliers must take all reasonable steps to obtain information from the manufacturer
of the plant and pass this information on to the person to whom the plant is supplied. If this is not
available, the importer or supplier must undertake the necessary testing and examination required
under the WHS Act themselves.
6.2 Information about the safe use of plant
Importers and suppliers must give adequate information to each person to whom they provide or
supply the plant, concerning:
 the purpose for which the plant was designed or manufactured
 the results of any calculations, testing, analysis or examination
 any conditions necessary to ensure that the plant is without risks when used for a purpose
for which it was designed or manufactured or when carrying out any activity related to the
plant.
An importer or supplier must ensure that health and safety information from the designer or
manufacturer is passed on when supplying the plant. See section 3.7 for the type of information
that should be provided.
The information may be provided in user manuals and manufacturers' instructions.
The information should, wherever possible, be in plain English but it must always maintain the
accuracy and quality of the technical information.
6.3 Compatibility of plant
Some plant may be assembled from components from a variety of sources. The assembly of
these by a manufacturer could present a risk to health and safety. A manufacturer using
components from a variety of sources should provide the importer or supplier an assurance of
compatibility of components and that the plant is safe and without risk to health when used
properly. You should in turn pass this information on to the end user. If this information is not
available then you must undertake the relevant testing to ensure that risks to health and safety
are eliminated.
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6.4 Imported plant
Importers of plant must take all reasonable steps to obtain information from the manufacturer
about the purpose for which the plant has been designed and any conditions necessary to ensure
it is without risks to health and safety.
If the health and safety information is not provided to the importer by the original designer or
manufacturer, the importer assumes responsibility for supplying the information normally provided
and must undertake the necessary testing to obtain the information (see Sections 3.6 and 3.7 of
this Code).
The importer or supplier must inspect the plant in conjunction with any information provided by the
manufacturer, and undertake any testing specified by the manufacturer. Any risks identified during
inspection and testing must be eliminated or minimised so far as is reasonably practicable. The
person to whom the plant is supplied must be advised of any residual risks.
The importer must take all reasonable steps to ensure that the designer and manufacturer are
consulted in relation to any alterations made to the plant to control risk.
6.5 Design registration
R. 232: An importer must not supply plant that requires design registration unless the design of
that plant has been registered.
If the item of plant to be imported requires design registration under Schedule 5 of the WHS
Regulations, the importer must apply for and receive design registration before supplying the plant
to anyone within Australia (see section 3.8). This will require the importer to conduct any testing
and develop the information required for design registration if it is not available. The design
registration number must be provided to any person to whom the plant is supplied.
If the importer or supplier makes modifications to the plant, for example to ensure compliance with
Australian standards, they should take all reasonable steps to advise both the designer and
manufacturer of this.
When importing second-hand plant, the importer must ensure that the plant has been
manufactured in accordance with the original design (based on which the plant design was
registered). If the design is not the same or if the plant (as imported) has been modified to the
extent that the safety has been compromised, the original plant design registration number must
not be used. The duty holders must engage a competent person to verify the new or modified
design and if necessary, register the new design.
6.6 Hire of plant
If you supply hired or leased plant (the ‘hirer’ or ‘lessor’) to an end user you have the same
obligations as a supplier of new plant and ensure, so far as is reasonably practicable, that hired
plant is safe and without risk to health when used properly. A supplier must ensure the hired plant
is accompanied by information about the way the plant must be used to ensure health and safety,
if the information is available.
The hirer of plant should ensure the plant is inspected between hiring and that any maintenance
and repairs are carried out to minimise risks to health and safety. In the context of hired plant,
‘between’ means every time the plant is hired or leased, but does not include an extension to the
hiring or leasing period for the same user (that is, hiree or lessee).
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The supplier may consider an extension to the period of contract as being an extended lease
provided that appropriate mechanisms are put in place to ensure adequate inspection and
maintenance is carried out during the lease.
The supplier is required to ensure that any excessive wear or damage to the plant is identified and
rectified. Proper regard should be given to the designer's or manufacturer's specifications for
inspection and maintenance.
A regular testing program should be implemented. Testing should consider factors such as the
amount of use of the plant and the operating and environmental conditions during the period.
Where plant is to be transferred between hirees or lessees without being returned to the supplier's
depot, the supplier is required to ensure that the plant is inspected and maintained before
transfer. For example, this may be done "on-site" without returning the plant to the depot.
Where the plant is hired or leased for an extended period of time, the supplier should make
arrangements with the hiree or lessee to have the plant inspected and maintained, giving proper
regard to the designer's or manufacturer's specifications for inspection and maintenance.
With plant that is hired or leased with an operator, the supplier may fulfil their duty by preparing a
comprehensive set of checks, and authorising the operator to carry out these checks between
hiring and leasing. If this option is adopted, the supplier should ensure that the operator is
competent to apply the checks and carry out, or arrange to carry out, the maintenance identified
by the checks.
The supplier should ensure that records are kept of inspections and maintenance carried out on
the plant.
If agreement is reached that the hiree or lessee undertake the necessary inspections and
maintenance, the supplier should ensure that either during the hire or lease of the plant or at the
conclusion of the hire or lease, all records associated with inspections and maintenance of the
plant are obtained from the hiree or lessee.
6.7 Second-hand plant
Suppliers must provide the purchaser with any information relating to the safe use of the plant that
is in their possession. This should include information relating to commissioning, operation,
maintenance and systems of work. The information may consist of data sheets, test certificates,
operations and service manuals, reports and a safety manual.
Persons who conduct a business or undertaking involved in the supply of second-hand plant must
ensure, so far as is reasonably practicable, that any faults that cause a risk to health and safety
(including excessive wear and damage) are identified and rectified before supplying the plant.
Persons conducting a business or undertaking not involved in the supply of second-hand plant but
who decide to sell or transfer a piece of plant they have used must provide a written notice
outlining the condition of the plant, any faults identified and, if appropriate, that the plant should
not be used until the fault is rectified. This notice must be provided to the person to whom the
plant is supplied.
If second-hand plant is to be used for scrap or spare parts, the supplier must inform the person
they are supplying the second-hand plant to that the plant is being supplied as scrap or spare
parts and that the plant in its current form is not to be used as plant. This must be done in writing
or by marking the item of plant.
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Suppliers should identify any components of the plant that are unserviceable, or arrange to have
this done by a competent person. The components of the plant that are unserviceable may
constitute a hazard in the operation of the plant. If plant is identified as not fully serviceable, you
should inform the purchaser that the plant should not be used until the plant is fully serviceable.
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7
7.1
SPECIFIC RISK CONTROLS
Confined spaces
The design, manufacture or modification of any plant or structure that includes a confined space is
critical. Thoughtful design can eliminate the need to enter a confined space or eliminate the risk of
inadvertent entry and will therefore eliminate the associated risks.
R. 64: Designers, manufacturers and suppliers of plant or structures must eliminate the need to
enter a confined space and eliminate the risk of inadvertent entry. If this is not reasonably
practicable, then:
 the need for any person enter the space must be minimised so far as is reasonably
practicable
 the space must be designed with a safe means of entry and exit, and
 the risk to the health and safety of any person who enters the space must be eliminated or
minimised as far as is reasonably practicable.
The following features should be incorporated in the design and manufacturing stages:
 use of lining materials that are durable, require minimal cleaning and do not react with
materials contained in the confined space
 design of mechanical parts to provide for safe and easy maintenance, to reduce the need
for persons to enter, and
 access points (including those within the confined space, through divisions, partitions or
obstructions) should be large enough to allow people wearing the necessary protective
clothing and equipment to pass through, and to permit the rescue of all people who may
enter the confined space.
Further guidance on confined spaces is available in the Code of Practice: Confined Spaces.
7.2
Manual tasks
R. 61: Designers and manufacturers must:
 design the plant to eliminate the need to carry out a hazardous manual task
 where this is not reasonably practicable, minimise the risk of musculoskeletal disorders
arising from hazardous manual tasks
 provide adequate information about the features of the plant that eliminate or minimise the
need for any hazardous manual task to be carried out.
The importer or supplier of plant must take all reasonable steps to obtain the information and
provide it to any person to whom the plant is supplied.
Designers and manufacturers should consider:
 characteristics such as the weight, size, shape, surface characteristics and stability of
plant or its various component parts. Where these characteristics present a risk to users,
plant should be equipped with items such as hand-grips, to enable it to be picked up and
moved safely and eliminate the risk
 vertical and horizontal reach distances of people who may use or manually handle plant
 requirements for operational controls/levers either on a console or inside a cabin
 conditions in which the plant will be used, serviced, maintained and repaired. For instance,
in some situations it may not be possible to make use of mechanical lifting devices and so
items of plant or their components should be designed to eliminate risk to the user/worker.
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Methods designers and manufacturers may consider to reduce risks associated with manual tasks
include:
 modular components designed to dismantle so that they can easily be carried or repaired
 attachments such as handles to make lifting easier or wheels to make moving easier
 using lightweight materials
 designated lifting points.
Further guidance is available in the Code of Practice: Hazardous Manual Tasks.
7.3
Noise
R. 59: A designer and manufacturer of plant must:
 design the plant so that its noise emission is as low as reasonably practicable
 provide information on the noise emission values of the plant (for example, data on sound
power level or sound pressure level), the operating conditions of the plant when the noise
emission is measured and the methods used to measure the noise emission.
They must also provide information on any conditions required for safe use.
The importer or supplier of plant must take all reasonable steps to obtain the information and
provide it to any person to whom the plant is supplied.
In eliminating or minimising the risks associated with noise, you should consider:

preventing or reducing the impact between machine parts

replacing metal parts with quieter plastic parts

combining machine guards with acoustic treatment

enclosing particularly noisy machine parts

selecting power transmission which permits the quietest speed regulation; for example,
rotation-speed-controlled electric motors, and

isolating vibration-related noise sources within machines.

good seals for doors for machines

machines with effective cooling flanges which reduce the need for air jet cooling

quieter types of fans or placing mufflers in the ducts of ventilation systems

quiet electric motors and transmissions

pipelines for low flow speeds (maximum 5m/sec.)

ventilation ducts with fan inlet mufflers and other mufflers to prevent noise transfer in the
duct between noisy and quiet rooms.
Further guidance is available in the Code of Practice: Managing Noise and Preventing Hearing
Loss at Work
7.4
Energy sources
The design should recognise and accommodate the possibility of a dangerous situation occurring
where the energy source to the plant fluctuates or the energy source is discontinued and then
resumed. In particular:
 the plant should default to the ‘off position,’
 if there is a risk of injury due to the plant restarting when the power resumes, the plant
should remain in a de-energised state until the start sequence is commenced,
 the plant should not be able to restart automatically after power fluctuations, and
 protective devices should remain fully effective before, during and after any change to the
status of the energy source.
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Where electrical equipment has been designed for use within certain voltage limits, only those
specific requirements such as electrical standards and statutory requirements that address the
design requirement should apply.
Where plant is powered by an energy source other than electricity, such as hydraulic, pneumatic,
thermal or stored kinetic energy, it should be designed to allow the plant to be constructed and
equipped so as to avoid all potential hazards associated with these types of energy.
7.5
Static electricity
Static electricity may cause an electric shock to a person. As a consequence the person may fall,
or drop an object. Static electricity may also cause unintended combustion, for example where
flammable fumes may be emitted. Where the build-up of potentially dangerous electrostatic
charges creates a risk to health and safety, plant should be designed to prevent or limit the
discharge, and/or be fitted with a discharging system. For example, spark detection and
suppression systems can be incorporated into dust extraction systems to minimise the risk of
explosion or fire.
7.6
Lightning
The design of plant that is likely to be exposed to lightning while being used should incorporate a
system for conducting any resultant electrical charges to earth.
7.7
Fire and explosion
Certain types of plant have the potential to be a fire or explosion risk. A designer should eliminate
or reduce risk of fire, overheating or explosion posed by the plant itself or by gases, liquids, dusts,
vapours or other substances produced or used by the plant or other plant nearby.
7.8
Plant capable of entangling an operator
Designers should make certain that moving parts of machines are designed in a way that
prevents operator contact that may cause injury. In some instances this may be difficult to achieve
as there may be a need to have rotating elements exposed during normal use.
Radial drills, surface planers and milling machines commonly operate with the rotating tool
unguarded and this presents a real risk of entanglement should the operator or the operators
clothing come into contact with the rotating part. The most likely causes of contact are where the
operator applies cutting lubricant to the interface between the tool and the part being machined,
removing swarf from around the part, or where the tool is not brought to a complete stop during
re-setting of the workpiece.
Modern metal-working machine tools often incorporate protective guards that surround the cutter
and provide lubricant and swarf removal that can eliminate the need for operator intervention and
in doing so, eliminate the risk of entanglement. Where plant is computer controlled, the need for
operator interaction is further reduced. Older style machines however, should be protected by the
use of, for example, physical barriers or pressure sensitive mats. Lubricant application and swarf
removal can also be achieved by the retro- fitting of additional devices dedicated to these
purposes and which allow the operator to remain outside the danger zone while the plant is
operating.
Woodworking machinery can also expose an operator to a risk of entanglement, especially when
workpieces are being fed into machines. Such risks can be eliminated by the use of powered feed
equipment that provides a safe distance between the operator from revolving cutters or blades.
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Plant such as grain augers or tree-limb mulchers also requires special attention to prevent
operators becoming entangled in the plant.
Controls for plant capable of entanglement should be able to bring the plant quickly to a complete
stop. Plant capable of causing entanglement must not be able to continue rotating once the stop
command is given.
7.9
Vibration
Plant should be designed to avoid any risks resulting from vibration. Vibration may be transmitted
to the whole body and particularly to hands and arms, when using plant. There are two
approaches you can use to control vibration:
 preventing vibration happening in the first place, and
 separating the vibration from the person using the plant.
Examples of prevention are substituting an internal combustion engine fitted to plant with an
electric drive.
Examples of separation are:
 suspended cabs, used on some commercial vehicles, and
 use of vibration isolation, for example, the use of rubber blocks or mounts on an engine to
reduce (isolate) the vibration.
7.10 Exposure to radiation
Plant should be designed so emission of any radiation is limited to the extent necessary for
operation of the plant and so there is no risk to health and safety from emissions. The effects of
radiation exposure are cumulative. Where necessary, instructions should be included stating the
need for regular personal monitoring for radiation build-up.
Radiation hazards are produced by a variety of sources and may be generated by non-ionising or
ionising radiations. Information on non-ionising and ionising radiation for particular items of plant
can be found in relevant Australian Standards. Plant should be designed so external radiation
does not interfere with its operation or with people working on or in the vicinity of the plant.
Lasers
Lasers are devices that produce optical radiation with unique properties. They have varying power
and applications. High power laser devices can present a hazard over considerable distances
from the source. While exposure to some higher powered laser products may cause skin burns,
most laser injuries are to the eyes. For example, some laser pointers available on the market are
of sufficient power to cause eye injury.
Laser products may consist of a single laser with or without its own power supply or multiple
lasers in a complex system.
R. 223: Lasers must be designed and installed to prevent accidental irradiation of any person.
The laser equipment must be protected so that any operator or other person is not exposed to
direct radiation, radiation produced by reflection or diffusion or secondary radiation. Visual
equipment used for the observation or adjustment of laser equipment on plant must not create a
risk to health or safety from laser rays.
All laser devices must be sold with appropriate information about their safe use. This generally
takes the form of a label with both the classification details and the warnings-for-use that are
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appropriate to that classification. The warning labels appropriate to the class should be
permanently affixed to the housing in a highly visible position.
Designers should consult with manufacturers, suppliers, owners and end users to ensure that the
correct strength of laser is used and the housing of the laser unit is designed according to safe
design principles. The designer should ensure that complete written information on the safe use of
laser products is provided to manufacturers, erectors, installers, suppliers, owners and end users.
Laser devices sold in Australia should be classified in accordance with AS/NZS 2211.1:1997
Laser safety - Equipment classification, requirements and user's guide.
Radio frequency radiation
Radio frequency radiation (RFR) is electromagnetic energy (wave) that is transmitted at
frequencies between 3 kHz and 300 GHz. Radio frequency (RF) generating plant may be used at
workplaces that perform forging, annealing, tempering, brazing or soldering, sealing of plastics,
glue drying, curing particle boards and panels, heating fabrics and paper, or cooking by means of
a microwave oven.
Workers in industrial workplaces that use RF generating plant are at risk of exposure to levels of
RF fields where radiation may cause adverse health effects. For example, RF fields greater than
10 MHz interact with human tissue to raise the temperature and cause heat stress related illness
such as impaired concentration, numbness, and eye damage. Usually those workers operating
the plant are the most likely to be exposed. However, workers who do not operate RF generating
plant but are situated within its vicinity and people coming into the workplace can also be at risk
from the generated radiation.
Pregnant women and people with metallic implants or cardiac pacemakers may be at particular
risk from RFR.
Ultraviolet radiation
Excessive exposure to ultraviolet (UV) radiation can cause not only sunburn but also lasting skin
damage, premature skin aging and an increased risk of developing skin cancer. UV exposure also
increases the risk of UV induced damage to the lens and cornea of the eye.
UVR exposure can also result from artificial sources for example, from germicidal lamps and
quartz-halogen lights. Designers need to identify ultraviolet risks associated with the plant they
are designing.
For example a designer of mobile plant should safeguard the driver from exposure to ultra
violet radiation by incorporating an effective canopy into the design in order to eliminate or
minimise the risk.
7.11 Risk of being trapped
Where there is a risk of a person becoming trapped or enclosed within the plant, measures should
be included to bring the plant to an immediate stop or prevent the plant being activated while a
person is in that position, for example presence sensing systems used together with control
systems that de-energise the plant. For mobile plant, the risk of the operator being trapped if the
plant overturns can be minimised with rollover protective structures.
7.12 Hazardous chemicals
Plant should be designed and manufactured to eliminate or minimise the release of any
substances which are hazardous. This extends to controlling hazardous waste.
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7.13 Combined plant
Where you have arranged plant to work in combination with other plant or parts of other plant, it
must be designed so that the stop controls, including the emergency stop control, can not only
stop the plant itself but all other plant related to the operation if the continued operation of the
plant can present a risk to the operator or others.
Designers must provide information about combined plant to the manufacturer and ensure that
the instructions for operating the plant provide guidance for end users.
7.14 Stability
Unstable plant is a hazard. It can topple, parts can fall off or it can unexpectedly move and result
in workers or others in the workplace suffering crushing or impact injuries.
Designers should ensure that plant is designed to be stable and without risk of overturning, falling
or unexpected movement during erection or installation and under all operating conditions. It may
be necessary for you to consult with other stakeholders such as manufacturers, erectors/installers
and end users.
Detailed erection, modification and dismantling procedures should be provided by the designer in
writing to prevent unstable plant at the workplace. Stability testing requirements for the pant can
be developed and specified at the design stage and verified after manufacture.
7.15 Mechanical or structural failure during operation
The various parts of plant and their linkages must be able to withstand the stresses to which they
are subjected during intended use and reasonably foreseeable misuse. The durability of materials
used to construct the plant must be adequate for the nature of the specified working environment.
In particular, when nominating the type of materials to be used, you must consider the possible
effects of fatigue, ageing, corrosion and abrasion.
The design specification must indicate the type and frequency of inspection and maintenance
required to keep the plant in a safe condition. The design specification must, where appropriate,
also indicate the parts subjected to wear and the criteria for determining replacement.
Where a risk of rupture or disintegration of component parts remains despite the measures taken,
the parts concerned must be mounted, positioned and/or guarded in such a way that in case of
rupture their fragments will not put the operator or others at risk.
Both rigid and flexible hoses/pipes carrying fluids such as gases or solids or a mixture of these,
particularly those under high pressure, must be able to withstand the foreseen internal and
external stresses and must be firmly attached and/or protected against those stresses.
Precautions must be taken to make sure that there is no risk posed by rupture.
Where material to be processed is automatically fed to moving parts of the plant, your design
must include means to avoid risks to the operator and others which may arise from the material
being ejected or being blocked in the moving parts of the plant. These means may include:
 allowing the moving parts to attain normal working condition before material comes into
contact with the moving parts, and
 coordinating the feed movement of the material and the moving parts of the plant at all
times including on start-up and shut-down regardless of whether the operation is
intentional or unintentional.
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7.16 Software
Designers considering the use of interactive software to be used by the operator to command or
control the operation of the plant should make sure that the software is as intuitive as possible
and not require complex manipulation that could be affected by repetition or fatigue.
7.17 Lighting
Lighting should be provided to enable safe use and operation of plant. Poor lighting can lead to
poor visibility, operator fatigue, wrong decisions and accidents. For example if an operator is
unable to clearly see a hopper capacity indicator, he or she may not empty it at the right time thus
creating a dangerous situation.
Emergency lighting should operate on its own power supply and not be subject to cuts in power.
Lighting may be internally or externally installed.
If external lighting needs to be provided in the workplace to ensure the safety of workers at or
near the plant, the designer should ensure that written information is provided to the
erector/installer and end user.
Technical standards cover lighting requirements for plant use, operation and maintenance,
including:
 the direction and intensity of lighting,
 the contrast between background and local illumination,
 the colour of the light source, and
 reflection, glare and shadows.
Technical standards also describe some specific situations where lighting design for use in
industrial settings must meet electrical safety standards. Standards also detail design
requirements to prevent lighting interactions causing a stroboscopic effect, particularly the
following examples:
 fluorescent lighting on moving plant which makes moving parts of machinery look as if
they are stopped, or
 rotating beacons in mobile plant in the internal environment.
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APPENDIX A – EXAMPLES OF TECHNICAL STANDARDS
The following table is a list of published technical standards that provide guidance on the design,
manufacture and use of certain types of plant. These technical standards provide guidance only
and compliance with them does not guarantee compliance with the WHS Act and Regulations in
all instances. This list is not exhaustive.
Plant Description
Reference Number
Standard Title
Amusement
Structures
Cranes, including
hoists and winches
AS 3533
AS 1418 (Series)
AS 4991 - 2004
AS 2550 (Series)
AS 1755 - 2000
AS 3000
Conveyers
Electrical
installation
Electrical
installation within
an industrial plant
Earthmoving
machinery
Design
Make
Use
Amusement Rides and Devices
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AS 2359 (Series)
Cranes Including Hoists and Winches
Lifting devices
Cranes – Safe use
Conveyers - Safety requirements
Electrical installation (known as the
Aust/NZ wiring rules)
Safety of machinery: Electrical
equipment of machines-General
requirements
Earthmoving machinery – Protective
structures - General
Earthmoving Machinery – Safety –
Wheeled machines-Brakes
Earthmoving machinery – Basic types –
Identification and terms and definitions
Earth-moving machinery - Definitions of
dimensions and codes - Part 1: Base
machine
Earth-moving machinery - Definitions of
dimensions and codes - Part 2:
Equipment and attachments
Earth-moving machinery - Tractorscrapers – Terminology and commercial
specifications
Power-actuated (PA) hand-held
fastening tools.
Hand-held motor operated electric tools
– Safety – General requirements
Industrial fall-arrest systems and
devices - Harnesses and ancillary
equipment
Industrial fall-arrest systems and
devices - Selection, use and
maintenance
Safety nets-Safety requirements, test
methods
Gas cylinders-General requirements
(known as SAA Gas Cylinders Code )
Gas cylinder test stations
LP (Liquefied Petroleum Gas) Fuel Vessels for Automotive Use.
Powered industrial trucks
AS 4488.2-1997
AS/NZS 2211 (Series)
AS 2397
AS/IEC 60204.1
AS 2294.1
AS 2958.1
ISO 6165
ISO 6746-1
ISO 6746-2
ISO 7133
Explosive Powered
tools
Hand-held electric
tools
Fall arrest
AS/NZS 1873 (Series)
AS/NZS 60745
AS/NZS 1891.1
AS/NZS 1891.4
BS EN 1263-1:2002
Gas cylinders
AS 2030.1-1999
AS 2337.2 -2004
AS/NZS 3509
Industrial (Forklift)
trucks
Industrial rope
access systems
Lasers
AS/NZS IEC 60825.1:
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Industrial rope access systems
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Safety of laser products
Safe use of lasers in the building and
construction industry
Safety of laser products – Equipment
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Plant Description
Reference Number
Standard Title
Lifts
2011
AS 1735 (Series)
classification and requirements
Lifts, escalators and moving walks
(known as the SAA Lift Code)
Safety of machinery
Fixed platforms, walkways, stairways
and ladders-Design, construction and
installation
Abrasive wheels-Selection, care and
use
Code of practice for the guarding and
safe use of metal and paper cutting
guillotines
Vapour degreasing plant – Design,
installation and operation – Safety
requirements
Low-voltage switchgear and control
gear, switches, disconnectors, switchdisconnectors and fuse combination
units
Functional safety of safety related
systems
Functional safety – Safety instrumented
system for the process industry sector
Safety of machinery: Functional safety
of safety-related electrical, electronic
and programmable electronic control
systems
Safety of machinery: Safety-related
parts of control systems-General
principles
Safety of machinery, Electro sensitive
protective equipment
Agricultural tractor power take-offs rear-mounted power take-off types 1, 2
and 3 - General specifications, safety
requirements, dimensions for master
shield and clearance zone
Agricultural wheeled tractors - Roll-over
protective structures criteria and tests
Tractors and machinery for agriculture
and forestry - Technical means for
ensuring safety - General
Overhead protection for agricultural
tractors - Test procedures and
performance requirements
Copper Boilers - Issue 7-2001
Steel Boilers – Issue 4-1995
Sub-Miniature Boilers – Issue 1-2008
Duplex Boilers – Issue 1-2010
Pressure Equipment
Boilers – Safety management and
supervision systems
Serially produced pressure vessels
Machinery
AS 4024 (Series)
AS 1657
AS 1788.2 -1987
AS 1893-1977
AS 2661-1983
AS/NZS 3947.3:2001
AS 61508.6 -2011
AS/IEC 61511
AS 62061
ISO 13849.1
BS/IEC 6496-2:1997
AS 1121.1:2007
AS 1636
AS/NZS 2153.1:1997
SAE J167-2011
Miniature boilers
Pressure
equipment
AMBSC Code –Part 1
AMBSC Code –Part 2
AMBSC Code - Part 3
AMBSC Code – Part 4
AS/NZS 1200:2000
AS 2593:2004
AS 2971:2007
AS/NZS 3788:2006
AS 3873 :2001
AS 3920.1-1993
Boiler and pressure vessels – In service
inspection
Boiler and pressure vessels – Operation
and maintenance
Assurance of product quality – Pressure
equipment manufacture
Design
Make
Use
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Plant Description
Reference Number
Standard Title
ASME I
ASME II
ASME V
ASME VII -1
ASME VII - 2
ASME VIII-1
ASME IX
ANSI / NGV-2
CSA B51 Part 2
ISO 11439:2000
ISO/EN 13458 (Series)
Pressure piping
AS 4041-2006
Machinery
guarding
AS 4024 (Series)
ISO 12100:2010
Scaffolding
Ladders
Spray painting
AS/NZS 1576.1:2010
AS 1577-1993
AS/NZS 4576
AS/NZS
1892.1/1892.2/1892.3
AS/NZS 4114.1
AS/NZS 4114.2
Turbines
BS/EN 60593-2:1996
API 612
Ventilation
AS 1668.2
Work boxes- crane
lifted
AS 1418.17
1996
AS 2550
AS 3860-1991
ISO 2374
Design
Make
Power boilers
Materials
Non-destructive examination
Pressure vessels
Pressure vessels – alternative rules
Pressure vessels – Full NDE – for
AS1210 class1h (h=1)
Welding and brazing qualifications
Basic requirement of compressed
natural gas vehicle fuel containers
High pressure cylinders for the on-board
storage of natural gas as a fuel for
automotive vehicles
High pressure cylinders for the on-board
storage of natural gas as a fuel for
automotive vehicles
Cryogenic vessels – Static vacuum
insulated vessels
Pressure piping
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Safeguarding of machinery – general
principles
Safety of machinery – General
principles for design
Scaffolding – general requirements
Scaffold planks
Guidelines for scaffolding
Portable ladders
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Spray painting booths. Part 1: Design,
construction and testing
Spray painting booths. Part 2:
Installation and maintenance
Rules for steam turbine acceptance
tests
Special purpose steam turbines for
refinery services
The use of ventilation and air
conditioning in buildings
Cranes (including hoists and winches)
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Cranes – Safe use
Fixed guideway people movers
Lifting appliances – Range of maximum
capacities for basic models
Use
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Key:
Abbreviations Name
ANSI
American National Standards Institute
API
American Petroleum Institute
AMBSC
Australian Miniature Boiler Safety Committee
AS
Australian Standard
ASME
American Society of Mechanical Engineers
AS/NZS
Australian Standard / New Zealand Standard
BS
British Standard
CSA
Canadian Standards Association
EN
Europaische Norm (European Standard)
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IEC
ISO
NZS
SAE
International Electrochemical Commission
International Standards Organisation
New Zealand Standards
Society of Automotive Engineers
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APPENDIX B – REGISTRABLE PLANT
List of Plant requiring registration of design as outlined in Schedule 5 (Part 1) of the WHS
Regulations
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Pressure equipment, other than pressure piping, and categorised as hazard level A, B, C
or D according to the criteria in Section 2.1 of AS 4343 Pressure equipment – hazard
levels
Gas cylinders covered by Part 1.1 of AS 2030.1 Gas cylinders - General Requirements
Tower cranes including self-erecting tower cranes
Lifts, including escalators and moving walkways
Building maintenance units
Hoists with a platform movement exceeding 2.4 metres, designed to lift people
Work boxes designed to be suspended from cranes
Amusement devices covered by Section 2.1 of AS 3533.1:2009 - Amusement Rides and
Devices, except Class 1 structures (see below)
Concrete placement units with delivery booms
Prefabricated scaffolding and prefabricated formwork
Boom-type elevating work platforms
Gantry cranes with a safe working load greater than 5 tonnes or bridge cranes with a safe
working load of greater than 10 tonnes, and any gantry crane or bridge crane which is
designed to handle molten metal or Schedule 10 hazardous chemicals
Vehicle hoists
Mast climbing work platforms
Mobile cranes with a rated capacity of greater than 10 tonnes
Note: The plant listed as requiring design registration does not include:
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a heritage boiler
a crane or hoist that is manually powered
an elevating work platform that is a scissor lift or a vertically moving platform
a tow truck
certain Class 1 structures including:
o playground structures
o water slides where water facilitates patrons to slide easily, predominantly under
gravity, along a static structure
o wave generators where patrons do not come into contact with the parts of machinery
used for generating water waves
o inflatable devices that are sealed
o inflatable devices that do not use a non-return valve.
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List of Plant items requiring registration as outlined in Schedule 5 (Part 2) of the WHS
Regulations
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Boilers categorised as hazard level A, B or C according to criteria in Section 2.1 of AS
4343 - Pressure equipment - hazard levels.
Pressure vessels categorised as hazard level A, B or C according to the criteria in Section
2.1 of AS 4343 - Pressure equipment - hazard levels, except for gas cylinders; LP Gas fuel
vessels for automotive use, and serially produced vessels.
Tower cranes including self-erecting tower cranes.
Lifts, including escalators and moving walkways.
Building maintenance units.
Amusement devices covered by Section 2.1 of AS 3533.1:2009 - Amusement Rides and
Devices, except for certain Class 1 structures (see below).
Concrete placement units with delivery booms.
Mobile cranes with a rated capacity of greater than 10 tonnes.
Note: The plant listed as requiring item registration does not include:
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a crane or hoist that is manually powered
certain Class 1 structures:
o playground structures
o water slides where water facilitates patrons to slide easily, predominantly under
gravity, along a static structure
o wave generators where patrons do not come into contact with the parts of machinery
used for generating water waves
o inflatable devices that are sealed
o inflatable devices that do not use a non-return valve.
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APPENDIX C – DESIGN SOURCES OF HUMAN ERROR
The following table lists some human errors that may be associated with the use of plant and the
possible causes due to poor design of the plant or systems of work associated with the plant.
Common human errors
Possible causes due to poor design
Inadvertent activation of plant.
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Several critical displays of
information are too similar or too
close together.
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Critical components installed
incorrectly.
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Inappropriate use or delay in use
of controls.
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Inadvertent activation of controls.
Critical instruments and displays
not read or information
misunderstood because of clutter.
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Failure to notice critical signal.
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Plant operation results in
unexpected direction or response.
Lack of understanding of
procedures.
Following prescribed procedures
results in error or incident.
Lack of correct or timely actions.
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Exceeding prescribed limitations
on load or speed.
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Lack of interlocks or time lockouts.
Lack of warning sign against activating
equipment under specified damaging conditions.
Errors of judgement, particularly during periods
of stress or high job demand.
Job requires operator to make hurried
judgements at critical times, without
programmed back-up measures.
Design and instructions are ambiguous on
installation of components.
Lack of asymmetrical configurations or guides on
connectors or equipment.
Critical controls are too close, similar in design,
awkwardly located.
Readout instrument blocked by arm when
making adjustment.
Labels on controls are confusing.
Information is too small to see from operator's
position.
Controls easy to activate by brushing past or too
close to other controls.
Controls can be easily activated accidentally.
Lack of guards over critical controls.
Critical instruments or displays not in most
prominent area.
Design of many displays similar.
Lack of suitable auditory and visual warning to
attract operator's attention to information.
Activation direction of controls conflicts with
population norms or expectancies.
Instructions are difficult to understand.
Written prescribed procedures not checked for
accurate operation.
Available information incomplete, incorrect or not
available in time.
Response time of system or plant too slow for
making next appropriate action.
Lack of automatic corrective devices on system
with fast fluctuations.
Lack of governors and other parameter limiters.
Lack of warnings on exceeding parameters.
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