Product Overview

Summary: This Exhaust System Maintenance Safe Operating Procedure sets out a clear, step-by-step approach for safely inspecting, servicing and maintaining exhaust systems in Australian workplaces. It helps control hazardous fumes, heat and noise, while supporting compliance with WHS legislation and plant maintenance requirements across workshops, commercial kitchens, manufacturing sites and vehicle fleets.

Poorly maintained exhaust systems can expose workers to hazardous gases, excessive heat, noise and fire risk, as well as lead to costly breakdowns and regulatory non-compliance. This Exhaust System Maintenance Safe Operating Procedure provides a structured, repeatable method for planning, conducting and documenting exhaust inspections, servicing and repairs in line with Australian WHS expectations. It covers fixed and mobile plant exhausts, vehicle exhaust systems, and local exhaust ventilation (LEV) associated with engines, generators and industrial equipment.

The SOP guides workers through pre-maintenance safety checks, isolation and lock-out requirements, safe access and handling of hot components, inspection criteria, leak detection, component replacement, and post-maintenance verification testing. It also embeds housekeeping, waste handling and record-keeping requirements so that businesses can demonstrate due diligence to regulators, clients and auditors. By standardising how exhaust systems are maintained, organisations reduce health risks from fumes and noise, extend equipment life, and create a safer, more reliable working environment for their teams.

Key Benefits

• Reduce worker exposure to hazardous exhaust emissions, fumes and heat through consistent inspection and maintenance.
• Ensure compliance with WHS legislation, plant maintenance duties and relevant Australian Standards for ventilation and noise.
• Minimise unplanned downtime, equipment failures and costly repairs by implementing a preventative maintenance regime.
• Standardise maintenance practices across sites and shifts, improving training, supervision and contractor management.
• Improve documentation and traceability of maintenance activities to support audits, incident investigations and warranty claims.

Who is this for?

• Workshop Managers
• Fleet Maintenance Supervisors
• Diesel Mechanics
• Automotive Technicians
• Plant and Maintenance Managers
• Facilities Managers
• Commercial Kitchen Managers
• WHS Advisors and Safety Officers
• Engineering and Maintenance Planners
• Operations Managers

Hazards Addressed

• Exposure to hazardous exhaust gases (e.g. carbon monoxide, nitrogen oxides, diesel particulate matter)
• Burns from contact with hot exhaust components and surfaces
• Fire and explosion risks from leaking fuel, oil or exhaust gases onto hot surfaces
• Noise exposure from defective or modified exhaust systems
• Manual handling injuries when removing or installing heavy exhaust components
• Falls from height when accessing elevated exhaust stacks or ducting
• Inhalation of dust, fibres or residues during exhaust and duct cleaning
• Crush and impact injuries from unsupported vehicles or plant during maintenance activities
• Electrical hazards associated with powered ventilation and extraction systems

Included Sections

• 1.0 Purpose and Scope
• 2.0 Definitions and Types of Exhaust Systems
• 3.0 Roles, Responsibilities and Competency Requirements
• 4.0 Applicable Legislation, Standards and Codes of Practice
• 5.0 Required Tools, Equipment and Personal Protective Equipment (PPE)
• 6.0 Pre-Maintenance Planning and Risk Assessment
• 7.0 Isolation, Lock-Out Tag-Out (LOTO) and Safe Access Procedures
• 8.0 Exhaust System Inspection Checklist and Acceptance Criteria
• 9.0 Maintenance and Servicing Procedures (Vehicles, Plant and Fixed Systems)
• 10.0 Cleaning, Filter Replacement and Ductwork Maintenance
• 11.0 Leak Detection, Repair and Component Replacement
• 12.0 Noise, Vibration and Performance Verification
• 13.0 Housekeeping, Waste Management and Environmental Considerations
• 14.0 Post-Maintenance Testing, Commissioning and Sign-Off
• 15.0 Emergency Procedures and Incident Response
• 16.0 Training, Competency and Supervision Requirements
• 17.0 Records, Maintenance Logs and Continuous Improvement

Legislation & References

• Work Health and Safety Act 2011 (Cth) and equivalent state and territory WHS Acts
• Work Health and Safety Regulations 2011 (Cth) and equivalent state and territory WHS Regulations – Plant and Structures, Hazardous Atmospheres and Noise
• Safe Work Australia – Code of Practice: Managing Risks of Plant in the Workplace
• Safe Work Australia – Code of Practice: Managing Noise and Preventing Hearing Loss at Work
• Safe Work Australia – Code of Practice: Managing the Work Environment and Facilities
• AS/NZS 1668.1: The use of ventilation and air conditioning in buildings – Fire and smoke control in multi-compartment buildings
• AS/NZS 1668.2: The use of ventilation and air conditioning in buildings – Mechanical ventilation in buildings
• AS/NZS 60079 series: Explosive atmospheres (where exhaust systems operate in hazardous areas)
• AS/NZS 4024 series: Safety of machinery
• AS/NZS 1269 series: Occupational noise management