Product Overview

Summary: This Borehole Drilling Safety Safe Operating Procedure sets out clear, practical steps for planning and conducting drilling activities safely on Australian worksites. It helps businesses control high‑risk hazards such as ground instability, rotating plant, pressurised fluids and remote or isolated work, while demonstrating due diligence under WHS legislation.

Borehole drilling is inherently high risk, involving powerful rotating equipment, unstable ground conditions, pressurised fluids, and often remote or environmentally sensitive locations. Without a structured safety procedure, businesses are exposed to serious incidents such as entanglement in rotating parts, struck‑by injuries from drill rods, uncontrolled release of drilling fluids, vehicle rollovers and falls into open boreholes. This Borehole Drilling Safety SOP provides a step‑by‑step framework to manage those risks from initial planning through to demobilisation, aligned with Australian WHS expectations and industry best practice.

Developed for drilling operations across civil, mining, quarrying, geotechnical and groundwater projects, this document translates legislative and standards requirements into practical actions for crews on the ground. It clarifies responsibilities, defines mandatory pre‑start checks, sets minimum controls for different drilling methods, and embeds safe systems of work for tasks such as rod handling, rig setup, working near services and managing drilling fluids and cuttings. By implementing this SOP, organisations can standardise their approach across sites, improve contractor management, and provide clear evidence of due diligence in the event of an audit or incident investigation.

The procedure is written in plain, field‑ready language suitable for toolbox talks and inductions, while still being robust enough for inclusion in WHS management systems and project safety plans. It supports businesses to protect their people, safeguard plant and the environment, and keep projects on schedule by reducing unplanned downtime due to incidents or equipment damage.

Key Benefits

• Ensure a consistent, defensible approach to borehole drilling safety across all projects and sites.
• Reduce the risk of serious injuries from entanglement, falls, struck‑by incidents and uncontrolled ground or fluid conditions.
• Demonstrate compliance with Australian WHS legislation and relevant drilling and machinery standards during audits and client reviews.
• Streamline induction and competency verification for drillers, offsiders and subcontractors with clear, task‑based instructions.
• Minimise costly downtime, rework and environmental damage through structured planning, equipment checks and emergency readiness.

Who is this for?

• Drilling Supervisors
• Drillers and Offsiders
• Site Supervisors
• Project Managers
• WHS Managers and Advisors
• Geotechnical Engineers
• Mining and Exploration Managers
• Civil Construction Managers
• Principal Contractors
• Health and Safety Representatives (HSRs)

Hazards Addressed

• Entanglement in rotating drill rods, augers and moving parts
• Crushing and pinch‑point injuries during rig setup, mast raising and rod handling
• Struck‑by hazards from falling or ejected rods, tools and equipment
• Falls into open boreholes, sumps and excavations
• Ground instability, borehole collapse and subsidence around the drill pad
• Uncontrolled release of pressurised drilling fluids, air or water
• Exposure to hazardous substances in drilling muds, cuttings or contaminated groundwater
• Noise‑induced hearing loss from continuous rig and compressor operation
• Whole‑body and hand‑arm vibration from prolonged operation of drilling plant
• Manual handling injuries from lifting rods, casing, bags of additives and ancillary equipment
• Vehicle and mobile plant collisions or rollovers on uneven or remote terrain
• Contact with underground or overhead services (electricity, gas, water, telecommunications)
• Adverse weather exposure, heat stress and dehydration on remote or open sites
• Fatigue and isolation risks associated with remote and out‑of‑hours drilling operations
• Environmental contamination from spills, leaks and improper disposal of drilling fluids and cuttings

Included Sections

• 1.0 Purpose and Scope
• 2.0 References, Definitions and Abbreviations
• 3.0 Roles, Responsibilities and Competency Requirements
• 4.0 Pre‑Planning and Risk Assessment (JSEA/SWMS)
• 5.0 Site Access, Traffic Management and Services Location
• 6.0 Drill Rig Selection, Mobilisation and Set‑Up
• 7.0 Pre‑Start Inspections and Safety Checks
• 8.0 Personal Protective Equipment (PPE) Requirements
• 9.0 Safe Operating Procedure – General Drilling Activities
• 10.0 Rod Handling, Casing Installation and Extraction
• 11.0 Managing Ground Conditions and Borehole Stability
• 12.0 Drilling Fluids, Compressed Air and Pressure Control
• 13.0 Working in Remote or Isolated Locations
• 14.0 Environmental Protection and Waste Management
• 15.0 Hazard Identification and Control Measures
• 16.0 Lockout/Tagout and Isolation of Plant
• 17.0 Emergency Preparedness and Response (e.g. entanglement, collapse, spill, medical)
• 18.0 Incident Reporting, Investigation and Corrective Actions
• 19.0 Training, Induction and Competency Verification
• 20.0 Monitoring, Review and Continuous Improvement

Legislation & References

• Work Health and Safety Act 2011 (Cth and relevant state/territory variants)
• Work Health and Safety Regulation 2011 (and state/territory equivalents)
• Safe Work Australia – Code of Practice: Managing the Risk of Plant in the Workplace
• Safe Work Australia – Code of Practice: Excavation Work
• Safe Work Australia – Code of Practice: Managing Noise and Preventing Hearing Loss at Work
• Safe Work Australia – Code of Practice: Hazardous Manual Tasks
• Safe Work Australia – Code of Practice: Managing Risks of Hazardous Chemicals in the Workplace
• AS 4024 series: Safety of machinery
• AS/NZS 4801: Occupational health and safety management systems (superseded but still commonly referenced)
• AS/NZS ISO 45001: Occupational health and safety management systems
• AS 2865: Confined spaces (where drilling intersects confined space work, e.g. pits or sumps)
• AS 1940: The storage and handling of flammable and combustible liquids (for fuel and certain drilling additives)
• Relevant state/territory legislation and guidelines for drilling, mining and exploration (e.g. NSW Resources Regulator, Qld Resources Safety & Health)