Product Overview

Summary: This Fibreglass Lamination Safe Operating Procedure provides a clear, step-by-step method for carrying out laminating tasks safely, consistently and in line with Australian WHS requirements. It helps control exposure to hazardous resins, solvents and fibreglass dust while improving product quality and workflow efficiency in composite manufacturing and repair environments.

Fibreglass lamination is a core process in many Australian industries, including marine, automotive, construction, and manufacturing. It involves handling resins, catalysts, reinforcements and solvents that can present significant health, fire, and environmental risks if not properly controlled. This Fibreglass Lamination Safe Operating Procedure sets out a structured, repeatable method for planning, preparing and carrying out lamination work so that every job is done safely and to a consistent standard.

The procedure addresses the real-world challenges faced in workshops and on-site environments: managing strong odours and vapours, controlling overspray and dust, preventing skin and eye contact with chemicals, and maintaining good housekeeping in confined or poorly ventilated spaces. It clarifies who is responsible for each stage of the process, what PPE is required and when, and how to set up ventilation, mixing stations and lay‑up areas to minimise risk. By implementing this SOP, businesses can demonstrate due diligence under Australian WHS legislation, reduce the likelihood of injuries and near misses, and support higher-quality laminates with fewer defects, rework and warranty claims.

Designed for practical use on the floor, this SOP supports toolbox talks, onboarding of new staff and refresher training for experienced laminators. It can be easily integrated into existing WHS management systems, risk registers and safe work method statements (SWMS), providing a clear reference point for audits, incident investigations and continuous improvement activities.

Key Benefits

• Reduce worker exposure to hazardous resins, solvents and fibreglass dust through clearly defined control measures.
• Ensure compliance with Australian WHS legislation and relevant standards for hazardous chemicals, ventilation and PPE.
• Standardise lamination practices across teams to improve product quality and reduce defects, rework and waste.
• Minimise the risk of fires, spills and chemical incidents by detailing safe storage, handling and mixing procedures.
• Support effective training, supervision and competency assessment for new and existing fibreglass laminators.

Who is this for?

• Fibreglass Laminators
• Composite Technicians
• Boat Builders and Marine Repair Technicians
• Manufacturing Supervisors
• Workshop Managers
• WHS Managers and Advisors
• Production Managers
• Maintenance and Facilities Managers
• Apprentices and Trainees in Composites and Marine Trades

Hazards Addressed

• Inhalation of styrene and other resin vapours
• Skin and eye contact with resins, catalysts and solvents
• Inhalation and skin irritation from fibreglass dust and fibres
• Flammable and explosive atmospheres from vapours and solvents
• Manual handling injuries from handling moulds, rolls and finished components
• Slips, trips and falls from resin spills, offcuts and poor housekeeping
• Chemical burns from peroxide catalysts and cleaning agents
• Respiratory sensitisation and dermatitis from repeated chemical exposure
• Noise exposure from trimming, grinding and cutting cured laminates
• Environmental contamination from improper disposal of resins, solvents and fibreglass waste

Included Sections

• 1.0 Purpose and Scope
• 2.0 Definitions and Abbreviations
• 3.0 Roles and Responsibilities
• 4.0 Required Competencies and Training
• 5.0 Equipment, Materials and Safety Data Sheets (SDS)
• 6.0 Personal Protective Equipment (PPE) Requirements
• 7.0 Pre-Start Checks and Area Preparation
• 8.0 Ventilation, Extraction and Environmental Controls
• 9.0 Resin, Catalyst and Solvent Handling and Mixing Procedures
• 10.0 Step-by-Step Fibreglass Lamination Procedure
• 11.0 Trimming, Finishing and Curing Controls
• 12.0 Hazard Identification and Risk Control Measures
• 13.0 Housekeeping, Waste Management and Spill Response
• 14.0 Emergency Procedures (Exposure, Fire, Spills)
• 15.0 Inspection, Quality Control and Documentation
• 16.0 Maintenance of Equipment and PPE
• 17.0 Review, Audit and Continuous Improvement

Legislation & References

• Work Health and Safety Act 2011 (Cth) and corresponding state and territory WHS Acts
• Work Health and Safety Regulations 2011 (Cth) – Hazardous Chemicals and General Workplace Management
• Safe Work Australia – Managing Risks of Hazardous Chemicals in the Workplace: Code of Practice
• Safe Work Australia – Managing the Work Environment and Facilities: Code of Practice
• Safe Work Australia – Managing Noise and Preventing Hearing Loss at Work: Code of Practice
• AS/NZS 1715: Selection, use and maintenance of respiratory protective equipment
• AS/NZS 1716: Respiratory protective devices
• AS/NZS 2161: Occupational protective gloves
• AS/NZS 1337.1: Personal eye protection
• AS/NZS 3833: Storage and handling of mixed classes of dangerous goods in packages and intermediate bulk containers
• AS 1940: The storage and handling of flammable and combustible liquids
• Globally Harmonized System of Classification and Labelling of Chemicals (GHS) as implemented in Australia