Product Overview

Summary: This Safety Operating Procedure sets out clear, practical rules for the safe selection, setup and use of ladders and work platforms in metal workshops. It helps Australian businesses control fall risks around welding bays, fabrication areas and maintenance tasks, while demonstrating compliance with WHS obligations and protecting workers from preventable injuries.

Falls from height remain one of the leading causes of serious harm in Australian metal fabrication and engineering workshops, even when the height involved is relatively low. In busy metal shops, workers regularly climb ladders or step onto mobile platforms to access overhead racks, welding jigs, ducting, cranes, lighting, and plant for inspection or repair. When this work is carried out among sharp edges, hot work, heavy sections and moving plant, even a short fall can have life‑changing consequences. This Ladder and Platform Safety in Metal Workshops SOP provides a clear, workshop‑specific framework for managing these risks in line with Australian WHS expectations.

The procedure covers the full lifecycle of ladder and platform use in a metalworking environment: from selecting the right equipment for the task and inspecting it for damage (including contamination from weld spatter, grinding sparks and metal swarf), through to correct setup, safe use and controlled storage. It addresses common metal workshop scenarios such as accessing high racking, working around overhead cranes, using platforms near welding fumes and grinding sparks, and maintaining fixed plant at height. By implementing this SOP, businesses can standardise safe practices across shifts, improve induction and refresher training, reduce incident rates, and provide documented evidence of a systematic approach to fall prevention during audits, regulator visits or incident investigations.

Key Benefits

• Reduce the risk of falls, strains and crush injuries associated with ladder and platform use in metal workshops.
• Ensure consistent, compliant practices across all workers, shifts and workshop areas when working at height.
• Demonstrate due diligence with documented procedures that align with Australian WHS legislation and guidance.
• Improve equipment life and reliability through structured inspection, maintenance and storage requirements.
• Support faster onboarding of new staff and apprentices with clear, metal‑workshop‑specific safety instructions.

Who is this for?

• Workshop Managers
• Fabrication Supervisors
• Boilermakers
• Metal Fabricators
• Maintenance Technicians
• Apprentice Metalworkers
• WHS Advisors and Safety Officers
• Engineering Managers
• Health and Safety Representatives (HSRs)

Hazards Addressed

• Falls from ladders or platforms while accessing high racks, plant or structures
• Ladders slipping, sliding or tipping on smooth concrete or contaminated floors
• Contact with overhead cranes, hoists, suspended loads or moving plant while on a ladder or platform
• Loss of balance due to overreaching, carrying tools or handling long metal sections at height
• Trips and slips caused by metal swarf, oil, coolant, welding spatter or offcuts around ladder bases
• Electric shock from using conductive metal ladders near live electrical equipment or welding leads
• Impact with sharp edges, hot work, grinders or welding arcs during elevated tasks
• Musculoskeletal injuries from incorrect manual handling of heavy or awkward mobile platforms

Included Sections

• 1.0 Purpose and Scope
• 2.0 References, Definitions and Legislative Requirements
• 3.0 Roles and Responsibilities (PCBU, Supervisors, Workers, HSRs)
• 4.0 Types of Ladders and Platforms Used in Metal Workshops
• 5.0 Hazard Identification and Risk Assessment for Work at Height
• 6.0 Equipment Selection Criteria (Ladders vs Platforms vs Alternative Controls)
• 7.0 Pre-use Inspection and Tagging Requirements
• 8.0 Safe Setup of Ladders and Platforms in Workshop Environments
• 9.0 Safe Use Procedures – Ladders
• 10.0 Safe Use Procedures – Mobile and Fixed Platforms
• 11.0 Working Near Overhead Cranes, Hoists and Suspended Loads
• 12.0 Controls for Slips, Trips, Contamination and Housekeeping
• 13.0 Use of Tools, Materials and PPE While Working at Height
• 14.0 Isolation, Barricading and Signage Requirements
• 15.0 Storage, Maintenance and Removal from Service of Damaged Equipment
• 16.0 Training, Competency and Induction Requirements
• 17.0 Incident Reporting, Investigation and Corrective Actions
• 18.0 Review, Audit and Continuous Improvement of the SOP

Legislation & References

• Work Health and Safety Act 2011 (Cth) and equivalent state and territory WHS Acts
• Work Health and Safety Regulations 2011 (Cth) – Part 4.4 Falls
• Safe Work Australia – Code of Practice: Managing the Risk of Falls at Workplaces
• Safe Work Australia – Code of Practice: Managing Risks of Plant in the Workplace
• AS/NZS 1892.1: Portable ladders – Metal
• AS/NZS 1892.2: Portable ladders – Portable ladders for general industrial use
• AS/NZS 1576: Scaffolding (relevant parts for mobile platforms and access equipment)
• AS/NZS 1657: Fixed platforms, walkways, stairways and ladders – Design, construction and installation