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Maintenance of Plant and Equipment at Height Risk Assessment

Maintenance of Plant and Equipment at Height Risk Assessment

  • • 100% Compliant with Australian WHS Acts & Regulations
  • • Fully Editable MS Word & PDF Formats Included
  • • Pre-filled Content – Ready to Deploy Immediately
  • • Customisable – Easily Add Your Logo & Site Details
  • • Includes 2 Years of Free Compliance Updates

Maintenance of Plant and Equipment at Height Risk Assessment

Product Overview

Identify and control organisational risks associated with Maintenance of Plant and Equipment at Height through a structured, management-level WHS Risk Management approach. This Risk Assessment supports compliance with the WHS Act, demonstrates Due Diligence, and helps protect your business from operational and legal liability.

Risk Categories & Hazards Covered

This document assesses risks and outlines management controls for:

  • WHS Governance, Roles and Consultation: Assessment of leadership responsibilities, PCBU obligations, consultation arrangements, and clarity of roles for managing work at height maintenance activities.
  • Planning, Design and Engineering of Access Systems: Management of design-stage decisions for fixed ladders, walkways, platforms and anchor points to ensure safe access for plant and equipment maintenance.
  • Structural Integrity and Roof / Bridge Surface Management: Evaluation of load ratings, fragile surfaces, corrosion, penetrations and inspection regimes for roofs, bridges and elevated structures.
  • Fall Prevention, Fall Arrest and Edge Protection Systems: Governance of guardrails, fall arrest systems, anchor layouts, harness use, inspection schedules and hierarchy of control for working at height.
  • Access Equipment Selection, Procurement and Maintenance: Protocols for selecting, purchasing and maintaining ladders, EWP/MEWPs, scaffolds and temporary platforms used for plant and equipment servicing.
  • Competency, Training and Authorisation for Work at Height: Systems for verifying licences, height safety training, refresher programs and formal authorisation of workers and supervisors.
  • Work Planning, Permits and Authorisation to Work at Height: Implementation of permit-to-work systems, job planning, isolation verification and pre-start checks before commencing maintenance at height.
  • Environmental and Site Conditions: Management of weather, wind, heat/cold, trees, traffic interfaces and other site-specific factors that impact safe access and maintenance at height.
  • Isolation, Lockout and Services Management: Controls for energy isolation, lockout/tagout, refrigerants, electrical services and utilities associated with plant and equipment located at height.
  • Contractor and Supplier Management: Assessment of contractor pre-qualification, inductions, supervision and performance monitoring for external parties conducting height-related maintenance.
  • Emergency Response, Rescue and First Aid for Work at Height: Planning for rescue from height, suspension intolerance, retrieval equipment, first aid capability and coordination with emergency services.
  • Health, Fatigue and Fitness for Work: Evaluation of medical fitness, fatigue management, medications and other human factors affecting safe performance of maintenance at height.
  • Housekeeping, Materials Handling and Dropped Objects Control: Systems to control tools and materials, prevent dropped objects, manage exclusion zones and maintain clear access ways.
  • Documentation, Record Keeping and Continuous Improvement: Management of procedures, inspection records, training logs, incident reviews and corrective actions to drive ongoing improvement in height safety.

Who is this for?

This Risk Assessment is designed for Business Owners, Facility Managers, Asset Managers and Safety Officers responsible for planning, approving and overseeing maintenance of plant and equipment at height across their operations.

Hazards & Risks Covered

Hazard Risk Description
1. WHS Governance, Roles and Consultation
  • • Lack of clear WHS policy for maintenance of plant and equipment at height
  • • Unclear WHS roles, responsibilities and delegations between PCBU, principal contractor and subcontractors
  • • Inadequate consultation with workers, Health and Safety Representatives (HSRs) and contractors about height-related risks
  • • Failure to consider WHS Act 2011 due diligence duties at senior management level
  • • Insufficient resourcing for safe systems of work (budget, time, competent people)
  • • No formal process to review and approve work at height methodologies for specialised tasks (e.g. bridge maintenance near trees, cold room/freezer tops)
2. Planning, Design and Engineering of Access Systems
  • • Plant, structures and cold rooms/freezers designed without safe permanent access for maintenance at height
  • • Reliance on ad-hoc or temporary access solutions (e.g. ladders, makeshift platforms) instead of engineered systems
  • • Inadequate consideration of bridge geometry and nearby trees when designing access methods for bridge maintenance
  • • Lack of edge protection, anchor points or walkways on top of cold rooms and freezers over 2 metres and over 6 metres
  • • Incompatible access systems for installed plant (e.g. equipment positioned beyond safe reach from platforms)
  • • Failure to consider safe rescue access in design (limited space, obstructions, fragile or insulated panels)
3. Structural Integrity and Roof / Bridge Surface Management
  • • Unknown load capacity of cold room and freezer roofs or bridge elements used for access
  • • Deteriorated or damaged structural components (e.g. corroded steel, rotten timber, delaminated insulated roof panels)
  • • Fragile surfaces (e.g. skylights, aged sheet roofing, thin insulated panels) not identified or controlled
  • • Uncontrolled build-up of ice, condensation or water on cold room/freezer roofs creating slip risks
  • • Vegetation and tree growth impacting bridge structures, scuppers or walkways and contributing to decay or instability
  • • Inadequate inspection and maintenance regime for structural elements used as work platforms
4. Fall Prevention, Fall Arrest and Edge Protection Systems
  • • Absence or inadequacy of guardrails, barriers and edge protection on elevated work areas
  • • Poorly designed or incorrectly installed fall arrest systems (anchors, static lines, harnesses) on roofs and bridges
  • • Failure to differentiate control requirements between work above 2 metres and above 6 metres on cold room/freezer roofs
  • • Inadequate system for inspection, testing and recertification of fall protection equipment and anchor points
  • • Reliance on administrative controls (signs, supervision) where engineering controls are reasonably practicable
  • • Lack of documented rescue and retrieval procedures in case of fall arrest activation
5. Access Equipment Selection, Procurement and Maintenance
  • • Use of unsuitable access equipment (ladders, MEWPs, scaffolds, bridging units) for the specific maintenance task
  • • Ageing or poorly maintained access equipment increasing risk of structural failure or malfunction
  • • Inconsistent procurement standards leading to mixed quality and non-compliant equipment across sites
  • • Failure to account for environmental conditions (wind, uneven ground, proximity to trees and powerlines) when selecting equipment for bridge work
  • • Inadequate inspection and tagging systems for mobile scaffolds, EWP’s and temporary platforms used on and around cold rooms
  • • Limited availability of appropriate plant leading to workarounds and unsafe substitutions
6. Competency, Training and Authorisation for Work at Height
  • • Workers and supervisors carrying out maintenance at height without appropriate formal training or experience
  • • Lack of verification of competency for specialised tasks (bridge access, tree interface, cold room/freezer roof systems, EWP operation)
  • • Insufficient training on specific fall protection systems and rescue procedures
  • • Inadequate instruction on cold room/freezer-specific hazards such as thermal stress, condensation and fragile panels
  • • Contractors engaged without adequate competency assessment or licence validation
  • • Failure of supervisors to recognise unsafe behaviours or non-compliance due to limited height safety knowledge
7. Work Planning, Permits and Authorisation to Work at Height
  • • Unplanned or reactive maintenance activities at height occurring without adequate risk assessment
  • • Absence of a formal permit-to-work system for high-risk tasks (e.g. work over 2 metres on cold stores, work over 6 metres, bridge works near traffic or trees)
  • • Inadequate consideration of interaction with other activities (traffic, crane operations, refrigeration plant operation)
  • • No requirement for pre-start coordination meetings or toolbox talks for complex multi-contractor works at height
  • • Poor documentation and control of changes to method, equipment or environmental conditions during the task
  • • Work occurring outside normal hours without appropriate supervision and support
8. Environmental and Site Conditions (Weather, Trees, Traffic, Temperature)
  • • Adverse weather (wind, rain, lightning, heat, cold) affecting stability of access equipment and worker safety at height
  • • Bridge locations exposed to live traffic, river systems or steep embankments compounding fall consequences
  • • Proximity of trees to bridge maintenance areas causing struck-by, entanglement or unplanned contact with EWPs and access structures
  • • Extreme temperatures and thermal gradients around cold rooms and freezers contributing to ice formation, condensation and thermal stress for workers
  • • Poor visibility (night work, fog, shadows) increasing likelihood of slips, trips and missteps at height
  • • Insufficient monitoring and escalation procedures when environmental conditions deteriorate
9. Isolation, Lockout and Services Management (Energy, Refrigerants, Utilities)
  • • Uncontrolled movement or energisation of plant during maintenance at height (e.g. conveyor start-up, fan operation, bridge components)
  • • Exposure to live electrical systems, overhead powerlines or concealed wiring while working near or on structures at height
  • • Release of refrigerants, cold air, steam or other hazardous substances from systems associated with cold rooms and freezers
  • • Contact with overhead or underground services when positioning EWPs, cranes or scaffolds for bridge and roof access
  • • Inadequate lockout/tagout procedures and poor coordination between maintenance, operations and contractors
10. Contractor and Supplier Management
  • • Engagement of contractors for specialised height work without adequate pre-qualification or WHS capability assessment
  • • Inconsistent safety standards between principal contractor and specialist contractors leading to confusion or lowest-common-denominator practices
  • • Reliance on contractors’ generic SWMS that do not adequately cover bridge-specific or cold room/freezer roof risks
  • • Poor communication of site-specific hazards (trees adjacent to bridges, traffic patterns, fragile roof areas, refrigeration plant layout)
  • • Lack of monitoring and enforcement of contractor compliance with agreed systems of work and permits
11. Emergency Response, Rescue and First Aid for Work at Height
  • • Delayed or ineffective rescue of a worker suspended in a fall arrest system, leading to suspension intolerance or further injury
  • • Inability to access injured workers on bridge structures or on top of cold rooms/freezers in a timely and safe manner
  • • Lack of coordination with emergency services regarding complex access environments (bridges over water, confined spaces around plant, height above 6 metres)
  • • Inadequate first aid capability for injuries associated with falls, hypothermia, heat stress or contact with structures
  • • Absence of drills and practical testing leading to unrealistic or unworkable emergency plans
12. Health, Fatigue and Fitness for Work
  • • Workers undertaking maintenance at height while fatigued, distracted or under the influence of alcohol or drugs
  • • Medical conditions (e.g. vertigo, cardiovascular disease, musculoskeletal issues) not identified or considered when allocating tasks at height
  • • Heat stress or cold stress for workers on bridge structures or cold room/freezer roofs, impacting concentration and physical capability
  • • Psychological stress or fear of heights leading to poor decision-making or non-compliance with safe systems of work
  • • Insufficient breaks, hydration and rotation for prolonged maintenance tasks at height
13. Housekeeping, Materials Handling and Dropped Objects Control
  • • Poor housekeeping on bridge decks and roofs leading to slips, trips and falls at height
  • • Uncontrolled tools, equipment or materials falling from height and striking people below or damaging plant
  • • Inadequate systems for securing temporary components (guardrails, panels, covers) during maintenance
  • • Improvised manual handling of equipment to and from elevated areas, including cold room/freezer roofs and bridge structures
  • • Limited exclusion zones or barricades to separate overhead work from workers, traffic and public
14. Documentation, Record Keeping and Continuous Improvement
  • • Inadequate documentation of risk assessments, inspections, certifications and permits for work at height
  • • Failure to capture and analyse incidents, near misses and non-conformances related to maintenance at height
  • • Outdated or inconsistent procedures and SWMS not reflecting current plant configuration, bridge conditions or cold room/freezer layouts
  • • Lack of traceability of training, competency and equipment certification records for audit and legal defence
  • • Missed opportunities to learn from internal and industry-wide height incidents

Need to add specific hazards for your workplace?

Don't worry if a specific hazard isn't listed above. Once you purchase, simply log in to your Client Portal and add your own custom hazards at no extra cost. We take care of the hard work—creating the risk ratings and control measures for free—to ensure your document is compliant within minutes.

Legislation & References

This document was researched and developed to align with:

  • Work Health and Safety Act 2011
  • Work Health and Safety Regulations 2017
  • Managing the Risk of Falls at Workplaces Code of Practice: Guidance on controlling fall risks and implementing the hierarchy of control.
  • How to Manage Work Health and Safety Risks Code of Practice: Framework for identifying, assessing and controlling WHS risks.
  • Managing the Work Environment and Facilities Code of Practice: Requirements for safe access, egress and work environments.
  • AS/NZS ISO 31000:2018: Risk management — Guidelines.
  • AS 1891 (Series): Industrial fall-arrest systems and devices, including harnesses, lanyards, anchorages and system design.
  • AS/NZS 1657: Fixed platforms, walkways, stairways and ladders — Design, construction and installation.
  • AS/NZS 1892 (Series): Portable ladders — Selection, safe use and maintenance requirements.
  • AS/NZS 2550 (Series): Cranes, hoists and winches — Safe use, including elevated work platforms where applicable.
  • AS 3745: Planning for emergencies in facilities.
Standard Risk Assessment Features (Click to Expand)
  • Comprehensive hazard identification for all activities
  • Risk rating matrix with likelihood and consequence analysis
  • Existing control measures evaluation
  • Residual risk assessment after controls
  • Hierarchy of controls recommendations
  • Action priority rankings
  • Review and monitoring requirements
  • Consultation and communication records
  • Legal compliance references
  • Sign-off and approval sections

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