Pre-fabricated metal

building manufacturing information and

October 2010
checklist

Introduction How are people in

In 2010 WorkSafe conducted an inspection campaign in the prefabricated your industry getting
metal building manufacturing industry aimed at improving safety and health
issues within the industry. The following newsletter was developed to hurt?
identify safety issues in the industry and to assist you in meeting the Manual handling accounts for 42% of all
requirements of the OSH legislation. lost time injuries and diseases in your
The checklists used by WorkSafe inspectors during this campaign are industry (based on the five year period
included in this newsletter. Please use the checklists to ensure your total).
workplace meets the occupation safety and health legislation.
Issues covered by the checklists include: What is a risk assessment?
• Electrical
• Hazardous substances (chemical hazards-personal protective The occupational safety and health laws
equipment, ventilation, labels, containers, storage, signs, and material require risk assessments to be carried out.
safety data sheets)
A risk assessment is the process of
• Manual handling (eg lifting) determining whether there is a risk
• Mobile plant associated with an identified hazard, that
is, whether there is any likelihood of
• New and young workers
injury or harm. The process should
• Working from height include consultation with people involved
• Slips trips and falls in the task, as well as consideration of
• Machine guarding the experience and training of the
operator, individual tasks to be
• First aid and amenities
performed and the length of time the
• Fire and emergency safety operator is exposed to the identified
Further information can be obtained by contacting WorkSafe on 9327 8777 hazards.
or by visiting the website at [Link]

How do I use these checklists?

1. Use the checklists in this newsletter to inspect your workplace. You may see other hazards as you are going through – add them
to the checklist.
2. Anything that you have ticked ‘No’ or added to the list needs to be fixed. So, look at each hazard using the table below to
prioritise identified hazards.

Risk rating table – for working out level of risk Use the vertical and horizontal columns to consider both the likelihood of injury or
harm to health and the consequences to work out the level of risk

Likelihood of injury or Consequences of any injuries or harm to health

harm to health
Insignificant eg no injuries Moderate eg first aid Major eg extensive injuries Catastrophic eg death

Very likely High Extreme Extreme Extreme

Likely Moderate High Extreme Extreme
Moderate Low High Extreme Extreme
Unlikely Low Moderate High Extreme
Highly unlikely (rare) Low Moderate High High

Risk assessment is a 'best estimate' on the basis of available information. It is important the responsible person undertaking a risk assessment has
the necessary information, knowledge and experience of the work environment and work process, or such a person is involved.
3. If the hazard falls into ‘high’ or ‘extreme’, based on your view of how likely it is someone will get hurt and what level of injury
could happen, then you need to fix it straight away.
If it is lower down in the table – moderate or low – then plan when you will fix it.
Remember hazards have to be controlled – you can’t ignore them.

Westcentre 1260 Hay Street

West Perth WA 6005
Telephone: 1300 307 877
Facsimile: (08) 9321 8973
Email: safety@[Link]
Manual tasks and SLIPS
TRIPS AND FALLS 2

Manual tasks How do I reduce the risk of injury from

manual tasks?
Workplace injuries most commonly linked to manual tasks
include sprains and strains, hernias and damage to the back. The first step, in consultation with your workers, is to
identify the manual task hazards for your organisation.
Such injuries are a major cause of lost time at work and This can be done via review of reviewing past hazard
make up almost one-third of Western Australia’s workers’ or incident forms; analysing previous injury records for
compensation claims. In the five years to 1999-2000, staff; talking with workers about tasks they find difficult
almost seven million days were lost from work in WA as a or demanding; reviewing previous pre-service home
result of manual handling injuries; and a total of 132,819 risk assessments and observing staff while they
workers’ compensation claims were made at an average complete common tasks to collect information.
cost of $18,000 each.
In their inspection, our inspectors will be looking for the
‘Manual handling tasks’ is more than just keeping your key elements detailed in the checklists. Following the
back straight and knees bent, or lifting properly – it same checklist yourself will help you identify any
involves safely carrying, pushing and pulling, and holding shortcomings in your procedures or training and correct or
or restraining. update them; thus getting you started on meeting your
Just as manual tasks involve more than just lifting, so the health and safety requirements.
things that affect the risk of injury involve more than just Next, in consultation with staff, identify trends and
the weight of the objects handled. Factors such as determine which tasks are higher risk/priority. For each
awkward movements, fixed postures and how long and task, complete a risk assessment to identify which risk
quickly a task is performed are also very important. factors are present for that task. Risk factors may be
Injuries can be the result of gradual wear and tear (eg from actions & postures; forces & loads; vibration; work
frequent or prolonged activities), or sudden damage (eg from environment; systems of work; and worker characteristics
a single lift of something very heavy or awkward to handle or – please refer to the WA Code of practice Manual tasks
from tripping and falling while carrying an object. for more information. The risk assessment should also
determine what consequences/harm may result from
Jobs involving physical stress or repetitive movements have performing that task, and how likely it is that this harm
the highest rates of manual task injuries – over half the lost occurs.
time injuries involving nurses and health care workers,
cleaners, packers and store persons, are manual task injuries. Finally, for each hazard, determine what controls are
needed to minimise risk. Controls may involve:
Because of the high potential for manual tasks to cause lost 1. eliminating the hazard or hazardous task
time injuries, WorkSafe WA has identified this as one of
2. re-designing, modifying, altering or substituting
seven areas to be given priority when our inspectors visit
the hazard or hazardous task
your workplace.
3. administrative controls where the above controls
are not practical

What risk factors contribute to slips and How can I reduce the risk of slips and
trips incidents? trips in my workplace?
Slips and trips account for 20% of all lost time injuries There are many controls that employers can use to prevent
every year. They can result in serious injuries and lengthy slips and trips in the workplace. Firstly though, it is
periods of time off work. important to complete hazard identification and a risk
Risk factors that contribute to slips and trips injuries will assessment in consultation with your staff. This will ensure
vary according to the type of workplace and work tasks that the right control is chosen for the hazards that are
being completed. relevant in YOUR workplace.

Common risk factor categories include: Common safety measures used in workplaces include:
• Floor surface & condition 1. installing more power points to avoid cords on floor,
• Floor contamination widen aisles
• Objects on the floor 2. resurfacing floors with ‘less hazardous materials’
• Ability to see floor/ walkways/ hazards 3. restricting access to some work areas
• Cleaning/ spill containment 4. improve lighting, mark walkways install drainage and
• Space & design use ramps
• Stairs & stepladders 5. ensure good housekeeping - clean up spills immediately
• Work activities, pace & processes and use signs for slippery or wet floors
• Footwear & clothing 6. proper footwear
• Individual factors
 3
Machine SAFETY
Machine guarding Lock-out and tagging
Employers, manufacturers, designers and suppliers of Locking out of equipment or machinery is the most
machinery and equipment are legally required to make effective way of preventing it becoming operational
sure dangerous parts are safely guarded so that operators during maintenance. Its effectiveness lies in the "one key
and others are protected from injury. per lock, one lock per person" procedure.
A guard may be any shield, cover, casing, physical or If there is only one key per lock, the key has to be with
electronic barrier intended to prevent contact between a the person carrying out the maintenance. Where more
hazardous machine part and any part of a person or a than one person is working on equipment or machinery a
person’s clothing. multi-lock system should be followed, ensuring that each
person has attached a "personal" lock to the equipment
Control the risk or machine's multi-lock switch.
Old machinery is sometimes poorly guarded. Hazard areas All workplaces must have a system unless the equipment
may include extra moving parts like shafts, sprokets and or machinery is fully inoperative and then disconnected
pulleys that have been added for other uses. Original from the energy source.
guarding may have also been removed for maintenance
and not put back. There may be times when an operator Essentially, there are two types of tag, the "DANGER"
may need to reach over, under, around or into a machine tag and the "OUT OF SERVICE" tag.
while it is running. If so, any moving parts or other hazards
Australian Standard 1318 - 1985 recommends specific
must be appropriately guarded from human contact.
colours for the marking of physical hazards and the
Some of the hazards associated with machinery and likely identification of certain equipment in industry. Colours
to cause injury include: used are red, yellow, green and blue.
• Rotating PTO and other shafts, for example joints, • RED AND WHITE: Signifies danger and
couplings, shaft ends and crank shafts. prohibition, fire protection equipment, stop
buttons for electrical switches and emergency
• Gearing, including friction roller mechanisms, cables, stop controls for machinery.
sprockets, chains, clutches, cams or fan blades.
• YELLOW AND BLACK: Signifies caution: draws
• Keyways, keys, grease nipples, set-screws, bolts or attention to such hazards as unfastened or
any other projections on rotating parts. removed machinery guards.
• Any pulley or flywheel that incorporates openings, • GREEN AND WHITE: Denotes safety and
spokes or protrusions, etc, that renders it anything location of safety or first aid equipment.
except totally smooth.
• BLUE AND WHITE: Is for information signs
• Any crushing or shearing points, such as augers, roller where there is no specific hazard.
feeds, and conveyor belts.
Are isolating switches provided, and are lock-out and
• Rotating knives, blades, tines or similar parts of power tagging procedures used during maintenance work on
driven machines that operate in or near the ground. machinery such that:
• Any machine component that cuts, grinds, pulps, • isolation switches are switched off?
crushes, breaks or pulverises.
• switches are locked out and tagged to inform
• Hot parts of any machine. others that maintenance work is being done?
• Machinery being accidentally started during
maintenance. (for more information see guidance note
• the only key to the lock is in the possession of
the person carrying out the maintenance?
Isolation of plant.)

The Commission for The Commission for

Occupational Safety and Health Occupational Safety and
has released a code of practice Health has recently
for safeguarding of machinery. released a guidance note:
This publication is available on Isolation of plant. This
the WorkSafe’s website publication is available on
[Link] the WorkSafe’s website
[Link]
Forklift SAFETY 4

Safe movement of
Is your licence to operate a vehicles at workplaces
forklift current? Vehicles and mobile plant moving in
and around workplaces cause far too
The National Standard for Licensing Persons Performing High Risk Work
many occupational injuries and
(the National Licensing Standard) requires operators of forklifts to hold a
deaths in WA.
National Licence. Previously forklift operators in WA were issued with National
Certificates of Competency on a non-compulsory basis. Reversing, loading, unloading and
pedestrian movements are the
Is your training current? activities most frequently linked to
If you or a member of your staff have a forklift qualification issued prior to accidents.
31 December 1998 you will need to obtain a licence a National licence to perform To avoid incidents, traffic and
high risk work. Listed below are the dates when certificates are required to pedestrian movement needs to be
have been converted to an high risk work licence. designed, planned and controlled.
Here are some tips for safe
Date of issue of the O.H.S. movement of vehicles:
Date that certificate must be
Certification Australia card and
converted (commencement date • Design traffic routes so they are
Western Australian 'State' Certificate
being 1 October 2007)
of Competency wide enough for the largest
vehicle using them. They should
Between 1 January 1999 – be one-way (if possible) and
30 June 2010
31 December 2001 have clearly signed traffic
instructions.
Between 1 January 2002 - 31 December
2004
30 June 2011 • Separate pedestrian footpaths or
walkways from traffic or make
Between 1 January 2005 - 30 September traffic routes wide enough for
30 June 2012 both vehicles and pedestrians.
2007
Use pedestrian barriers to
prevent people walking in front
Working safely with forklifts guidance note of vehicles.
The Commission for Occupational Safety and Health has updated its Guidance • Situate loading bays where
note: Working safely with forklifts to be consistent with the new laws covering vehicles can be manoeuvred easily
high risk work. This guidance note is available from WorkSafe’s publications and protected from adverse
officer on 9327 8775 or free of charge on the website, [Link] weather conditions. Raised loading
(type ‘Working safely with forklifts’ into the 'search box). platforms should be fitted with rails
and raised wheel stop edges on
the non-loading sides, to prevent
How are workers getting hurt people, forklifts or trolleys rolling
The major safety issues using forklifts are: over the edge.

• co-workers/pedestrians being hit by moving forklifts or moving parts of a • Mark reversing areas so drivers
forklift; and pedestrians can see them
easily. To reduce reversing
• co-workers/pedestrians being trapped or caught between a moving accidents, place fixed mirrors at
forklift/moving parts of a forklift and stationary object; blind corners.
• operators suffering muscular stress due to a combination of • Ensure that people directing
inappropriate seating, vibration and manual handling; traffic wear high-visibility clothing
• operators falling while getting into or out of forklifts; and that their signals can be
• collisions between forklifts and other vehicles or stationary objects;
• forklift operators and others being hit by falling objects. Over the next twelve months
In addition, evidence suggests the following also cause injuries are caused WorkSafe inspectors visiting
by:
workplaces will be checking
• the operator’s body protruding from the cab and hitting an object; and to ensure forklift drivers have
• forklifts tipping over. current licence

Regular updates on OSH

WorkSafe has introduced a service that provides information on occupational safety and health direct to your email. By
subscribing to these bulletins you can receive information that is specific to your areas of interest.
Would you like to subscribe to receive this service? Go to [Link] ÆservicesÆmailing lists
Materials handling in
5
METAL MANUFACTURING
Storing steel
The storing of steel poses numerous potential problems that may easily lead to injury if appropriate controls are not in place.
Hazards include the potential for steel in its various forms to roll, slip, slide or fall over if not suitably restrained. Additional
hazards are posed if racking or other equipment provided for storage is unsuitable for the weights involved.
Shelving and racking systems for the safe storage of steel should be engineer designed to meet all relevant standards and be
secured to the floor or other fixtures.
• Open racking systems should be cross-braced to prevent collapse.
• Bollards should be provided to prevent damage by forklifts to corners of racks.
• The safe load for any racking system should be clearly displayed in a prominent position.
• Heavy items should be stored on the lower racks.
• Loading of any cantilever racking should be equal from both sides.
• Fixtures must be maintained in good working order.
If a pack of material has to be split the remaining material can be safely restrained by the use of "U" shaped metal gluts.
Flat steel may be stored upright on its end in a specially constructed rack. Appropriate means of access may be required to
the top of stored product for the attachment of plate clamps in a safe manner, where this type of system is used. It is good
work practice to offset the plates in such a rack to help facilitate the attachment of plate clamps, especially when steel plates
may need to be physically barred apart to allow access to those stacked on the inner.
Solid steel bar, large diameter pipes and coiled steel pose a greater problem due to their potential to roll if disturbed. Steel in
these forms can be safely stored on cantilever racks with a slight incline providing they are not double stacked. The rack arms
should be angled up to prevent the product rolling off, or stops provided to restrain movement. Heavy products should be
stored at lower levels to ensure stability.
Large steel pipes can be safely stored lying flat and chocked with suitable hardwood wedges or alternatively, secured in
specially designed pipe cradles. Large steel pipes should always be transported in specially designed cradles. The scalloped
design also allows the pipes to be stacked in a pyramid type arrangement that provides stability during loading and
transportation.

Warning on
stacking practices Further information
• Code of practice First aid-workplace amenities-personal
protective clothing
In January 2008 a 37-year-old man • Code of practice - Managing noise at workplaces
died when he was struck by steel that
fell when racking collapsed. • Code of practice - Manual tasks
• Code of practice - Safeguarding of machinery and plant
WorkSafe would like to remind
workplaces that it is crucial that • Code of practice - Violence aggression and bullying at work
stacked goods are secured in position • Code of practice - Working hours
and do not exceed their capacity to • Guidance note - Alcohol and other drugs at the workplace
remain in place because the outcome
• Guidance note - General duty of care
may be tragic.
• Guidance note - Isolation of plant
Employers whose workplaces include
• Guidance note - Material safety data sheets (MSDS
areas where goods are stacked need to
ensure the risk of injury is minimised by • Guidance note - Preparing for emergency evacuations
using a system for securely racking • Guidance note - Working alone
and/or strapping the goods. • Guidance note - Working safely with forklifts
The risk of manual handling injuries • The First Step – (a basic guide to help you get started with
from stacking needs to be minimised, managing safety and health at work
and workers engaged in the storage,
movement and handling of heavy
materials need to be adequately
trained to undertake the tasks safely.
WorkSafe strongly urges employers to
ensure that safe systems of work are in
place and implemented at all times to
minimise the risk of any further deaths
or serious injuries which may involve
the stacking of goods.
 6

Electricity safety checklist

check yes no n/a
Electrical installations are installed, constructed, maintained, protected (cover) and tested to
minimise the risk of electric shock or fire. Evidence of maintenance and testing in place.
Components clearly marked and switchboard free from obstructions.
Hand held portable equipment is protected by RCD (not construction)

Switchboard or fixed sockets marked whether RCD protected.

Maintenance program in place.

Flexible cords and extension cords are used in a safe manner

Connection moulded or transparent plug

Plugs, sockets and extension leads in good condition and protected from damage

Electrical installations are protected from damage that would increase the risk of electrical
shock or fire

The work is organised for the safety of employees and others at the workplace.

Work in the vicinity of power lines and plant (where applicable)

Hazardous substances safety checklist

check yes no n/a
Register of hazardous substances is complete (contents list and MSDS)

Register is readily available

Hazardous substances are properly labelled: manufacturers’ labels on container

Decanted containers labelled with name, risk and safety phrases

Risk assessment has been completed for all substances and recorded in register

Report is available where risk is significant

Practicable control measures have been implemented and maintained

Hierarchy of control is taken into account

People who may be exposed or work with hazardous substances have been provided with
adequate information, instruction and training

Record of training includes health effects, controls, safe work methods and PPE

Health surveillance is undertaken where appropriate

 7

Manual handling-lifting safety checklist

check yes no n/a
Practicable control measures have been implemented and maintained to eliminate or
reduce risk associated with manual handling work activity: ie hazard identification, risk
assessment and risk control conducted, employee feedback sought

Accident or hazard investigation is conducted

Everyone involved in organising and implementing manual handling process or tasks

where manual handling hazards have been identified have been provided with
adequate instruction and training (induction and ongoing training)

Mobile plant safety checklist

check yes no n/a
Mobile plant is maintained to minimise risks. Log book/records, pre-start checks

Evidence of training/instruction. Licence if high risk work.

The plant is a safe condition, eg plant registration, access to cab, seat and seat-belt,
FOPS/ROPS as required, loadchart as required, operator’s manual, controls labelled,
and guarding dangerous parts.
Work is organised for the safety of employees and others. Pedestrian control, traffic
management 2-way communication as required, and high-visibility clothing as required.
Site hazards are identified, assessed and controlled (ramps, slopes, rough ground,
power lines, excavations, ground load limits, and underground services)

New and young workers safety checklist

check yes no n/a
Induction, information, instruction and training emergency/evacuation procedures

Induction, information, instruction and training in hazard and accident reporting

Induction, information, instruction and training in how to reduce the risk of injury or
harm from hazards new/young workers may be exposed to in the course of their work

Induction, information, instruction and training in use, maintenance & storage of PPE

Supervision: ensure that new and young workers are working in accordance with safety
instructions including instructions re. skylarking, initiation ceremonies and bullying
Employers ensure the risk of injury or harm to (young) visitors is reduced by means
appropriate for the workplace and the type of work activity
 8

Working from heights safety checklist

check yes no n/a
Practicable control measures have been implemented and maintained to eliminate or reduce
the risk associated with work at heights

Hazard identification and risk assessment conducted?

Elimination of hazard considered?

Would a fall be arrested before contact with the ground or a structure?

Edge protection required if could fall > 2 metres from scaffold, fixed stairs, landing,
suspended slab, formwork, false-work. In any other cases of potential fall > 3 metres: FIPS
(catch platform, scaffold, safety nets, safety mesh, fall arrest system) or edge protection
provided.
There is safe means of access and egress to the work being performed at heights
Stairs, walkways, ladders, mechanical lifts, obstruction free
People required to work at height have been provided with adequate information, instruction
and training for the work being performed.

Slips trips and falls safety checklist

check yes no n/a
Floor or any stair or ramp has unbroken and slip resistant surface.
Special provisions for slip resistance provided in wet areas
Floor or any stair or ramp is free from any obstruction that may cause a person to fall (eg.
electrical leads, hoses and floor mounted power boxes in walkways, etc.)

Access to egress from workplace safe and at all times kept free from obstructions

Safe systems of work (eg. clean as you go policy) in place

Warning signs available and erected near spills

Guard rails or other safeguards provided on ramps and stairs

Appropriate PPE, such as slip resistant footwear, provided

Ramps in areas where height of floor levels change and trolley access required or items are
carried regularly
 9

Machine guarding safety checklist

check yes no n/a
Is every dangerous part of fixed, mobile or hand held powered plant (machinery) securely
fenced or guarded in accordance with Regulations 4.37 and 4.29, except where the plant is
so positioned or constructed that it is as safe as it would be if fenced or guarded?
Are adequate safe work procedures provided and documented to set, test and use
machinery during all cycles of production and maintenance? Look for:

• Pre-operational checks?

• If used, presence sensing system: safe system of work documented and a clearly
identified warning provided when guard is muted?
• If used, presence sensing system inspection and maintenance records
maintained?

• Appropriate isolation and lock-out procedures provided for maintenance?

• Where setting, testing and start-up of machinery is required with the final means
of safeguarding removed, have interim safeguards been provided?
• Where fixed physical guards are provided, is adequate provision made for
cleaning, maintenance, adjustment and repair?
• Where it is not practicable to guard machinery, is a safe system of work in place
for persons operating or passing in close proximity?
Are operators and maintenance personnel properly trained, familiar with the operation and
set up of the machinery and able to demonstrate safety features?
Are manufacturers’ decals, manuals and operator instructions readily available and in the
English language?

Is the highest level of guarding that is practicable being provided?

 10

Other issues safety checklist

check yes no n/a
Notifiable accidents reported to WorkSafe

LTI/LTD accidents and notified hazards investigated

Employees have received induction and on the job training

Passages/walkways kept free of obstructions

Access and egress (emergency exits) kept free of obstructions

Emergency egress enable safe egress in event of emergency / exit signs provided

Portable fire extinguishers provided and maintained

Evacuation procedures & diagram available and displayed and practised and training in the
use of fire extinguishers provided

Warning signs provided

Cleanliness and removal of debris

Surface and floors are unbroken and slip resistant to prevent slips and falls

All seating is maintained

Workplace facilities provided

Portable ladders according to AS 1892.1 (metal) or AS 1892.2 (wooden)

Gas cylinders secured

Flash back arrestors are fitted (oxy-acetylene or oxy-LPG)

PPE is provided, where necessary, and workers are trained in its use

PPE is maintained and stored appropriately

Noise
- Noise assessment conducted
- Control measures in place / avoid noise above exposure standard
- Provision of personal hearing protection (PHP)
- Instruction fitting, use, selecting, testing, maintenance and storage PHP
- Training on noise
Signage PPE according to AS 1319
First Aid box or facilities available and first aid trained person available

No smoking in enclosed workplaces

Location of any asbestos on site identified and the risk assessed

A1195515