Product Overview

Summary: This Dive Gear Maintenance Safe Operating Procedure sets out clear, practical steps for inspecting, cleaning, servicing, and storing diving equipment to keep workers safe in and under the water. It supports compliance with Australian WHS requirements and manufacturer specifications, helping you prevent equipment failure, decompression incidents, and other dive-related hazards before they occur.

Diving operations rely on life-support equipment that must perform flawlessly in harsh, high-pressure environments. Regulators, buoyancy compensators, cylinders, harnesses, and exposure suits all deteriorate over time through saltwater exposure, UV, contamination, and general wear and tear. This Dive Gear Maintenance Safe Operating Procedure provides a structured, repeatable approach to inspecting, cleaning, servicing, testing, and storing dive gear so that defects are identified and rectified before they place divers at risk. By formalising maintenance tasks, intervals, and responsibilities, your organisation can demonstrate due diligence and strong WHS governance for all diving-related activities.

The SOP is tailored for Australian workplaces involved in commercial, scientific, instructional, and recreational diving. It addresses common issues such as regulator free-flow, BCD failure, cylinder corrosion, contaminated breathing gas, and damaged harnesses or lines, and links maintenance practices back to risk controls required under WHS legislation. It also embeds record-keeping requirements, traceability for servicing and hydrostatic testing, and integration with your broader dive safety management system. Implementing this SOP helps you minimise the likelihood of in-water emergencies, support consistent training of staff, and maintain equipment in line with Australian Standards and manufacturer recommendations.

Key Benefits

• Reduce the risk of in-water equipment failure by implementing consistent pre- and post-dive inspection routines.
• Ensure compliance with Australian WHS obligations and relevant diving and pressure equipment standards.
• Extend the service life of expensive dive gear through correct cleaning, servicing, and storage practices.
• Standardise maintenance tasks across teams, improving training, accountability, and auditability.
• Improve diver confidence and operational readiness by maintaining well-documented, well-maintained equipment fleets.

Who is this for?

• Dive Supervisors
• Commercial Divers
• Scientific Divers
• Recreational Dive Instructors
• Dive Shop Owners and Managers
• Dive Equipment Technicians
• Marine Operations Managers
• WHS Managers in Marine and Aquatic Operations
• Emergency Services Dive Team Leaders
• Aquarium and Marine Park Operations Supervisors

Hazards Addressed

• Regulator malfunction or free-flow leading to loss of breathing gas supply
• Buoyancy compensator device (BCD) failure causing uncontrolled ascent or descent
• Cylinder rupture or valve failure due to corrosion or improper testing
• Exposure to contaminated breathing gas from poorly maintained cylinders or filling systems
• Entrapment or entanglement from damaged hoses, lines, or harness systems
• Thermal stress or hypothermia from degraded or leaking exposure suits
• Infection or skin irritation from poorly cleaned or shared equipment
• Manual handling injuries from improper lifting and storage of cylinders and heavy gear
• Slips, trips, and falls around wet maintenance and storage areas

Included Sections

• 1.0 Purpose and Scope
• 2.0 Definitions and Abbreviations
• 3.0 Roles and Responsibilities (Dive Supervisors, Technicians, Divers)
• 4.0 Applicable Legislation, Standards and Manufacturer Requirements
• 5.0 Dive Gear Inventory and Classification (Life-Support vs Ancillary Equipment)
• 6.0 Competency and Training Requirements for Maintenance Personnel
• 7.0 Pre-Dive Inspection Procedures for All Equipment
• 8.0 Post-Dive Cleaning and Decontamination Procedures
• 9.0 Regulator and Breathing Apparatus Maintenance
• 10.0 BCD, Harness and Weight System Maintenance
• 11.0 Cylinder Inspection, Hydrostatic Testing and Filling Controls
• 12.0 Exposure Suit, Gloves, Boots and Hood Care
• 13.0 Ancillary Equipment Maintenance (Masks, Fins, Computers, Lights, Reels)
• 14.0 Scheduled Servicing Intervals and Preventive Maintenance Planning
• 15.0 Storage, Transport and Handling Requirements for Dive Gear
• 16.0 Contaminated or Damaged Equipment Management and Tag-Out Process
• 17.0 Record-Keeping, Maintenance Logs and Traceability
• 18.0 Integration with Dive Safety Management Plans and Risk Assessments
• 19.0 Emergency Procedures Related to Equipment Failure
• 20.0 Review, Audit and Continuous Improvement of the SOP

Legislation & References

• Model Work Health and Safety Regulations (Safe Work Australia), including provisions for diving work and plant
• AS/NZS 2299.1: Occupational diving operations – Standard operational practice
• AS/NZS 1715: Selection, use and maintenance of respiratory protective equipment
• AS 2030.1: Gas cylinders – General requirements
• AS 3848 series: Filling of portable gas cylinders
• AS/NZS 1891 series: Industrial fall-arrest systems and devices (where harness systems are used in conjunction with dive operations)
• Manufacturer service manuals and recommended maintenance intervals for specific dive equipment brands