Product Overview

Summary: This Anti Corrosion Treatments Safe Operating Procedure provides a clear, step‑by‑step framework for safely preparing, applying and curing anti‑corrosion coatings on metals and other substrates. It helps Australian workplaces control chemical, fire and environmental risks while improving asset life, surface quality and compliance with WHS and environmental obligations.

Anti‑corrosion treatments are critical for extending the life of plant, equipment and structures in harsh Australian conditions, from coastal environments to industrial processing plants. However, the surface preparation, chemical handling and application techniques involved can introduce significant WHS and environmental risks if they are not tightly controlled. This Safe Operating Procedure sets out a practical, repeatable method for conducting anti‑corrosion work safely, including inspection and surface preparation, product selection, mixing and application, curing, clean‑up and waste disposal.

The procedure is designed for businesses that use primers, rust converters, inhibitors, protective coatings and related surface treatment systems, whether in workshops, depots or on live sites. It addresses common pain points such as inconsistent coating quality, uncontrolled exposure to solvents and isocyanates, flammable vapour risks, poor ventilation, and overspray and run‑off affecting adjacent workers or the environment. By implementing this SOP, organisations can demonstrate due diligence under Australian WHS law, standardise training and supervision, and protect both workers and high‑value assets from preventable damage and premature failure.

Structured to align with relevant Australian Standards and Safe Work Australia guidance, this SOP provides clear roles and responsibilities, pre‑start checks, PPE requirements, safe work methods and emergency response steps specific to anti‑corrosion treatments. It supports integration with existing Safe Work Method Statements (SWMS), permits to work, confined space procedures and hazardous chemicals registers, giving businesses a defensible, auditable framework for safe and effective corrosion control.

Key Benefits

• Ensure consistent, high‑quality anti‑corrosion treatment outcomes across all sites and shifts.
• Reduce worker exposure to hazardous vapours, mists and skin contact from primers, solvents and coating systems.
• Minimise the risk of fires, explosions and environmental contamination linked to flammable and hazardous chemicals.
• Demonstrate compliance with Australian WHS legislation and relevant standards for hazardous chemicals and spray painting.
• Streamline training, supervision and competency assessment for staff involved in surface preparation and coating application.

Who is this for?

• Maintenance Supervisors
• Workshop Managers
• Fabrication Supervisors
• Corrosion Technicians
• Industrial Painters and Coaters
• WHS Managers and Advisors
• Site Supervisors and Leading Hands
• Asset and Facilities Managers
• Marine and Offshore Maintenance Teams
• Plant and Operations Managers

Hazards Addressed

• Exposure to hazardous chemical vapours, mists and aerosols from coatings, rust converters and solvents
• Skin and eye irritation or chemical burns from direct contact with treatment products
• Respiratory sensitisation and asthma from isocyanate‑containing or solvent‑borne coatings
• Fire and explosion risks from flammable liquids and vapours during mixing and application
• Environmental contamination from spills, overspray, run‑off and improper waste disposal
• Manual handling injuries from moving and positioning heavy components, drums and equipment
• Slips, trips and falls due to overspray, spills, hoses and surface preparation residues
• Working at height risks when treating elevated structures, platforms or plant
• Noise and vibration from mechanical surface preparation (e.g. grinding, needle‑gunning, blasting)
• Eye and impact injuries from flying particles during mechanical cleaning and surface preparation

Included Sections

• 1.0 Purpose and Scope
• 2.0 Definitions and Abbreviations
• 3.0 Applicable Legislation, Standards and References
• 4.0 Roles, Responsibilities and Competency Requirements
• 5.0 Description of Anti‑Corrosion Treatments and Typical Applications
• 6.0 Pre‑Start Planning and Risk Assessment
• 7.0 Product Selection, Storage and Labelling Requirements
• 8.0 Required Tools, Equipment and Plant
• 9.0 Personal Protective Equipment (PPE) Requirements
• 10.0 Surface Inspection and Preparation Procedure
• 11.0 Mixing, Thinning and Pot Life Management of Coatings
• 12.0 Application Methods (Brush, Roller, Spray, Immersion) and Controls
• 13.0 Ventilation, Atmospheric Monitoring and Hot Work/No‑Ignition Controls
• 14.0 Quality Control, Coating Thickness and Cure Verification
• 15.0 Housekeeping, Spill Management and Waste Disposal
• 16.0 Working at Height and Access Equipment Requirements (if applicable)
• 17.0 Health Monitoring Considerations for Hazardous Substances
• 18.0 Emergency Procedures (Exposure, Fire, Spill, Equipment Failure)
• 19.0 Training, Induction and Competency Assessment
• 20.0 Recordkeeping, Inspection Logs and Review of Procedure

Legislation & References

• Work Health and Safety Act 2011 (Cth and corresponding state/territory legislation)
• Work Health and Safety Regulations 2011 (Hazardous Chemicals, Hazardous Atmospheres, Personal Protective Equipment)
• Safe Work Australia – Code of Practice: Managing Risks of Hazardous Chemicals in the Workplace
• Safe Work Australia – Code of Practice: Spray Painting and Powder Coating
• Safe Work Australia – Code of Practice: Managing the Risk of Falls at Workplaces
• AS/NZS 2312.1: Guide to the protection of structural steel against atmospheric corrosion by the use of protective coatings – Paint coatings
• AS/NZS 1715: Selection, use and maintenance of respiratory protective equipment
• AS/NZS 1716: Respiratory protective devices
• AS/NZS 2161 series: Occupational protective gloves
• AS/NZS 1337.1: Personal eye protection
• AS/NZS 60079.10.1: Explosive atmospheres – Classification of areas – Explosive gas atmospheres (for flammable vapour zones)