Product Overview

Summary: This Keel Installation Safe Operating Procedure provides a clear, step-by-step framework for safely installing keels on vessels in Australian shipyards, marinas and boatbuilding facilities. It focuses on structural integrity, lifting and rigging safety, and WHS compliance, helping you control high-risk activities while delivering consistent, high‑quality keel installations.

Keel installation is one of the most safety‑critical and structurally significant stages in vessel construction and repair. It involves complex lifting operations, precise alignment, confined work areas and the use of heavy tools and resins – all of which present serious risks if not tightly controlled. This Keel Installation Safe Operating Procedure sets out a practical, WHS‑aligned method for planning, preparing and executing keel installations on yachts, commercial vessels and recreational craft in Australian workplaces.

The SOP guides your team through each phase of the task: from pre‑lift planning, vessel support and stability checks, and inspection of lifting gear, through to controlled lifting, positioning, fastening, torquing, sealing and final inspection. It embeds hazard identification, risk controls and permit requirements into the workflow so that safe work becomes the default, not an afterthought. By adopting this SOP, marine businesses can demonstrate due diligence under WHS legislation, reduce the likelihood of dropped loads, structural failures or crush injuries, and ensure a consistent, survey‑ready standard of workmanship across all keel installation projects.

Key Benefits

• Ensure high‑risk keel lifting and installation work is carried out in line with Australian WHS expectations and marine industry best practice.
• Reduce the likelihood of dropped loads, crush injuries and vessel instability during keel handling and positioning.
• Standardise keel installation methods across teams, improving build quality, alignment accuracy and survey outcomes.
• Streamline training and onboarding for new shipwrights and yard workers with a clear, step‑by‑step procedure.
• Demonstrate due diligence to regulators, clients and marine surveyors through documented, repeatable safe work processes.

Who is this for?

• Shipwrights
• Boat Builders
• Marine Engineers
• Slipway and Boatyard Managers
• WHS Managers
• Marine Maintenance Supervisors
• Rigging and Lifting Coordinators
• Marine Surveyors
• Operations Managers – Shipyards and Marinas

Hazards Addressed

• Crush injuries from moving or suspended keels and associated lifting equipment
• Dropped loads due to rigging failure, incorrect slinging or unstable lifting configurations
• Vessel instability or tipping caused by inadequate hull support during keel removal or installation
• Manual handling injuries from handling keel components, fasteners and tooling
• Pinch and entanglement hazards around lifting slings, chain blocks and winches
• Exposure to hazardous substances such as resins, sealants, solvents and anti‑corrosive coatings
• Noise and vibration from power tools used for drilling, grinding and torquing fasteners
• Eye and skin injuries from metal swarf, dust and sharp edges on hulls and keels
• Slips, trips and falls on wet, uneven or cluttered slipways, hardstands and workshop floors
• Electrical hazards from portable power tools and extension leads used in damp marine environments

Included Sections

• 1.0 Purpose and Scope – Application to keel installation, replacement and major repairs
• 2.0 References, Definitions and Abbreviations – Key WHS and marine terminology
• 3.0 Roles and Responsibilities – Shipwrights, supervisors, riggers, spotters and WHS personnel
• 4.0 Required Competencies and Training – Licensing, high risk work and verification of competency
• 5.0 Tools, Equipment and Materials – Lifting gear, supports, fasteners, sealants and inspection requirements
• 6.0 Personal Protective Equipment (PPE) – Minimum and task‑specific PPE for keel installation activities
• 7.0 Pre‑Installation Planning – Risk assessment, permits, lift planning and communication arrangements
• 8.0 Vessel Support and Site Preparation – Chocking, blocking, cradle checks and work area housekeeping
• 9.0 Lifting and Rigging Setup – Selection, inspection and configuration of slings, spreader bars and lifting devices
• 10.0 Keel Alignment and Positioning – Step‑by‑step guidance for controlled lifting, manoeuvring and alignment
• 11.0 Fastening, Torquing and Sealing – Installation of bolts, torque procedures, corrosion protection and sealing
• 12.0 Hazard Identification and Control Measures – Specific controls for crush, chemical, manual handling and slip hazards
• 13.0 Quality Assurance and Inspection – Dimensional checks, structural verification and documentation for survey
• 14.0 Emergency Procedures – Response to dropped loads, injuries, chemical exposure and equipment failure
• 15.0 Environmental Considerations – Containment of spills, waste management and protection of marine environments
• 16.0 Documentation and Records – Checklists, lift plans, inspection records and training evidence
• 17.0 Review and Continuous Improvement – Periodic review, incident learnings and procedure updates

Legislation & References

• Work Health and Safety Act 2011 (Cth) and corresponding state and territory WHS legislation
• Work Health and Safety Regulations 2011 (Cth) – High Risk Work, Hazardous Substances and Plant
• Safe Work Australia – Code of Practice: Managing Risks of Plant in the Workplace
• Safe Work Australia – Code of Practice: How to Manage Work Health and Safety Risks
• Safe Work Australia – Code of Practice: Hazardous Manual Tasks
• Safe Work Australia – Code of Practice: Managing Noise and Preventing Hearing Loss at Work
• AS 2550 series: Cranes, hoists and winches – Safe use (for lifting operations where applicable)
• AS 4991: Lifting devices
• AS/NZS 1891 series: Industrial fall‑arrest systems and devices (where work at height is involved)
• AS/NZS 1715: Selection, use and maintenance of respiratory protective equipment
• AS/NZS 1716: Respiratory protective devices