Product Overview

Summary: This Metal Shredding Safety Safe Operating Procedure provides a clear, step‑by‑step framework for running metal shredders safely, compliantly and efficiently in Australian workplaces. It helps control the extreme risks associated with high‑energy shredding equipment, flying metal fragments and noise, while supporting consistent operations and demonstrable WHS due diligence.

Metal shredders are high‑energy machines that can turn scrap metal into manageable feedstock in seconds—but they also present significant safety risks if not controlled through robust procedures. Workers can be exposed to entanglement, ejection of metal fragments, fire and explosion from fuel residues, excessive noise, and crushing hazards from in‑feed systems and mobile plant. This Metal Shredding Safety Safe Operating Procedure sets out a practical, repeatable method for planning, operating, maintaining and shutting down metal shredders in line with Australian WHS expectations.

Developed for scrap yards, recycling facilities, demolition contractors and metal processing operations, this SOP translates legislative obligations into clear on‑the‑ground actions. It covers pre‑start inspections, lock out–tag out (LOTO), safe feeding techniques, guarding requirements, exclusion zones, noise and dust controls, and emergency response steps tailored to shredding operations. By implementing this procedure, businesses can significantly reduce the likelihood of serious injuries, plant damage and environmental incidents, while improving training consistency, contractor management and evidence of compliance during audits or regulator inspections.

Key Benefits

• Reduce the risk of serious injuries and fatalities associated with entanglement, crushing and ejected metal fragments.
• Ensure compliance with Australian WHS legislation and relevant Codes of Practice for plant, noise and hazardous chemicals.
• Standardise shredder start‑up, operation, cleaning and shutdown so all operators follow the same safe method of work.
• Improve incident preparedness with clear instructions for dealing with jams, fires, spills and mechanical failures.
• Support effective training, contractor induction and supervision through a documented, easy‑to‑follow procedure.

Who is this for?

• Metal Shredder Operators
• Recycling Plant Supervisors
• Scrap Yard Managers
• WHS Managers and Advisors
• Operations Managers
• Maintenance Technicians
• Health and Safety Representatives (HSRs)
• Compliance and Risk Managers

Hazards Addressed

• Entanglement in rotating shafts, cutters, conveyors and feed mechanisms
• Ejection of metal fragments, shrapnel and other projectiles from the shredding chamber
• Crushing and pinch‑point injuries around in‑feed hoppers, chutes and discharge conveyors
• Fire and explosion from fuel residues, oils, pressurised containers and combustible dusts
• Exposure to hazardous substances such as metal dusts, fumes, oils and hydraulic fluids
• Noise‑induced hearing loss from prolonged exposure to high noise levels
• Manual handling injuries from handling heavy or awkward scrap items and maintenance components
• Electrical hazards during maintenance, fault‑finding and unplanned interventions
• Mobile plant interaction risks from loaders, excavators and forklifts feeding the shredder
• Slips, trips and falls around work platforms, access ladders and material build‑up areas

Included Sections

• 1.0 Purpose and Scope
• 2.0 References, Definitions and Abbreviations
• 3.0 Roles and Responsibilities (PCBU, Supervisors, Operators, Maintenance, Contractors)
• 4.0 Description of Metal Shredding Plant and Process
• 5.0 Hazard Identification and Risk Controls Specific to Metal Shredding
• 6.0 Required Licences, Competencies and Training Requirements
• 7.0 Personal Protective Equipment (PPE) Requirements
• 8.0 Pre‑Start Checks and Area Preparation
• 9.0 Safe Start‑Up Procedure
• 10.0 Safe Operating Procedure – Feeding, Monitoring and Adjustments
• 11.0 Managing Jams, Blockages and Abnormal Conditions
• 12.0 Interaction with Mobile Plant and Traffic Management Controls
• 13.0 Noise, Dust and Hazardous Substances Controls
• 14.0 Safe Shutdown and Isolation Procedure
• 15.0 Cleaning, Clearing and Housekeeping Requirements
• 16.0 Maintenance, Inspection and Lock Out–Tag Out (LOTO) Procedures
• 17.0 Emergency Procedures – Fire, Explosion, Injury and Plant Failure
• 18.0 Incident Reporting, Investigation and Corrective Actions
• 19.0 Document Control, Review and Continuous Improvement

Legislation & References

• Work Health and Safety Act 2011 (Cth and harmonised state and territory Acts)
• Work Health and Safety Regulations 2011 (Cth and harmonised state and territory Regulations) – Plant and Structures, Hazardous Chemicals, Noise
• Safe Work Australia – Code of Practice: Managing the 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 Risks of Hazardous Chemicals in the Workplace
• AS 4024.1 Series: Safety of machinery (general principles, risk assessment, guarding and control systems)
• AS/NZS 4024.3610: Safety of machinery – Conveyors – General requirements
• AS/NZS 3000: Electrical installations (Wiring Rules)
• AS/NZS 1715: Selection, use and maintenance of respiratory protective equipment
• AS/NZS 1801: Occupational protective helmets
• AS/NZS 1270: Acoustics – Hearing protectors
• AS/NZS 2161 Series: Occupational protective gloves