Product Overview

Summary: This Safe Operating Procedure provides a clear, step-by-step framework for planning and carrying out confined space work in metal processing environments. It focuses on controlling atmospheric, engulfment and mechanical hazards while ensuring compliance with Australian WHS requirements and protecting workers undertaking high‑risk tasks such as tank entry, furnace maintenance and vessel cleaning.

Confined spaces in metal processing operations—such as furnaces, kilns, mixers, tanks, hoppers, ducts and pits—present a combination of hazards that can quickly become fatal if not rigorously controlled. Hot work residues, metal fumes, process gases, cleaning chemicals and residues from oils or coatings can all contribute to oxygen-deficient or toxic atmospheres, while moving plant, agitators and product build-up introduce serious engulfment and entrapment risks. This Confined Space Work in Metal Processing SOP is designed specifically for these conditions, providing a practical, WHS-aligned method for planning, authorising, executing and monitoring confined space tasks in foundries, fabrication shops, smelters and other metal processing facilities across Australia.

The procedure walks your team through hazard identification, atmospheric testing, isolation and lock-out of associated plant, ventilation, PPE requirements, communication protocols and standby arrangements. It clarifies roles and responsibilities between site management, permit issuers, entry supervisors, entrants, spotters and emergency responders, reducing ambiguity and ensuring each entry is properly controlled and documented. By implementing this SOP, businesses can demonstrate due diligence under WHS legislation, reduce the likelihood of catastrophic incidents, and provide workers and contractors with a consistent, defensible way of working in and around confined spaces integral to metal processing operations.

Key Benefits

• Ensure compliance with Australian WHS legislation and confined space Codes of Practice specific to high-risk metal processing environments.
• Reduce the risk of fatalities and serious injuries from atmospheric hazards, engulfment, entrapment and uncontrolled plant movement.
• Standardise confined space planning, permitting and entry controls across all shifts, contractors and work groups.
• Strengthen contractor management by setting clear expectations and controls for external trades working in your vessels, pits and tanks.
• Improve incident preparedness with defined communication, rescue and emergency response procedures tailored to metal processing plant layouts.

Who is this for?

• WHS Managers
• Operations Managers
• Metal Processing Plant Managers
• Maintenance Supervisors
• Confined Space Entry Supervisors
• Permit Issuers and Permit Receivers
• Fitters and Maintenance Technicians
• Boilermakers and Welders
• Production Supervisors
• Health and Safety Representatives (HSRs)
• Contractor Coordinators
• Emergency Response Team Leaders

Hazards Addressed

• Oxygen-deficient or oxygen-enriched atmospheres within furnaces, tanks, ducts and pits
• Exposure to toxic gases, vapours and fumes (e.g. welding fumes, combustion products, cleaning solvents, process gases)
• Flammable atmospheres from vapours, gases, metal dusts and residues in vessels and pipework
• Engulfment in powders, pellets, slag, scale, dust or product build-up in hoppers, bins and chutes
• Entrapment or crushing from moving agitators, screw conveyors, rotary kilns and other mechanical plant
• Heat stress from hot work and elevated temperatures within metal processing confined spaces
• Noise exposure and communication difficulties affecting coordination and emergency response
• Limited access and egress increasing rescue complexity and evacuation times
• Electrical hazards from portable tools, lighting and nearby live equipment
• Manual handling and awkward postures in restricted spaces leading to musculoskeletal injuries

Included Sections

• 1.0 Purpose and Scope
• 2.0 Definitions and Confined Space Criteria for Metal Processing Equipment
• 3.0 Roles and Responsibilities (PCBU, Supervisors, Entrants, Standby, Permit Issuers)
• 4.0 Pre-Work Planning and Risk Assessment
• 5.0 Confined Space Register and Identification of Metal Processing Confined Spaces
• 6.0 Permit-to-Work Process for Confined Space Entry
• 7.0 Isolation, Lock-Out/Tag-Out and Zero-Energy Verification of Plant
• 8.0 Atmospheric Testing, Monitoring and Ventilation Requirements
• 9.0 Personal Protective Equipment (PPE) and Respiratory Protection
• 10.0 Entry, Work and Exit Procedures for Confined Spaces
• 11.0 Hot Work, Welding and Cutting Controls in Confined Spaces
• 12.0 Communication, Standby Person and Continuous Monitoring Requirements
• 13.0 Emergency Response and Rescue Planning for Confined Spaces
• 14.0 Contractor Management and Induction for Confined Space Work
• 15.0 Training, Competency and Authorisation Requirements
• 16.0 Documentation, Records and Review of Confined Space Entries
• 17.0 Continuous Improvement and Incident Reporting

Legislation & References

• Safe Work Australia – Code of Practice: Confined Spaces
• Safe Work Australia – Code of Practice: Managing Risks of Hazardous Chemicals in the Workplace
• Safe Work Australia – Code of Practice: Welding Processes
• Model Work Health and Safety Regulations – Part 4.3 Confined Spaces
• AS 2865: Confined spaces
• AS/NZS 1715: Selection, use and maintenance of respiratory protective equipment
• AS/NZS 1716: Respiratory protective devices
• AS/NZS 60079.10.1: Explosive atmospheres – Classification of areas – Explosive gas atmospheres
• AS/NZS ISO 45001: Occupational health and safety management systems – Requirements with guidance for use