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Non-Destructive Testing Risk Assessment

Non-Destructive Testing 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

Non-Destructive Testing Risk Assessment

Product Overview

Identify and control organisational risks associated with Non-Destructive Testing (NDT) through a structured, management-level Risk Assessment that supports planning, governance and systems improvement across your operations. This document helps demonstrate Due Diligence under the WHS Act, reduce operational liability, and provide clear evidence of compliant WHS Risk Management for NDT activities.

Risk Categories & Hazards Covered

This document assesses risks and outlines management controls for:

  • WHS Governance, Legal Compliance & Due Diligence: Assessment of organisational responsibilities, consultation, safety leadership and verification of compliance for NDT operations across all sites.
  • NDT Method Selection, Job Planning & Engineering Review: Management of risk arising from inappropriate test method selection, inadequate job scoping, engineering sign-off and change management processes.
  • Radiation Safety & Regulatory Control (Industrial Radiography): Protocols for licensing, radiation management plans, dose constraints, exclusion zones, shielding and compliance with radiation regulators.
  • Strong Magnetic Fields & Electromagnetic Testing Management: Assessment of exposure to magnetic and electromagnetic fields, pacemaker and implant exclusions, equipment zoning and signage requirements.
  • Corrosion Testing & Materials Evaluation Systems: Management of risks associated with access to structures, confined or restricted areas, elevated work locations and integrity assessment programs.
  • Competency, Training & Certification of NDT Personnel: Systems for qualification, ongoing competency, supervision levels, authorisation to operate and verification of third-party certifications.
  • Plant, Equipment, Calibration & Maintenance Management: Control of NDT plant and instruments, inspection and test plans, calibration schedules, asset registers and defect isolation procedures.
  • Work Environment, Site Access & Interface with Other Operations: Assessment of shared work areas, traffic and plant interaction, access controls, isolation from production activities and site induction requirements.
  • Contractor, Subcontractor & Client Interface Management: Governance of roles and responsibilities, permit-to-work integration, pre-qualification, and coordination of NDT works within client systems.
  • Fatigue, Remote & After-Hours Work Management: Protocols for rostering, travel and remote work, lone worker systems, supervision and escalation during night or shutdown work.
  • Hazardous Chemicals, Consumables & NDT Waste Management: Management of penetrants, developers, solvents, couplants and other consumables, including storage, handling, SDS, and waste disposal controls.
  • Information Management, Reporting, Records & Data Integrity: Systems for traceability of inspections, secure storage of images and reports, version control, and protection against data loss or manipulation.
  • Emergency Preparedness & Incident Management for NDT Activities: Planning for radiation incidents, chemical spills, equipment failures, medical emergencies and notification to regulators and clients.
  • Health Monitoring, Radiation Dose & Occupational Exposure Management: Assessment of requirements for health surveillance, personal dosimetry, exposure records and review of cumulative dose trends.

Who is this for?

This Risk Assessment is designed for Business Owners, NDT Managers, Engineering Managers, Safety Professionals and Project Leads responsible for planning, approving and overseeing Non-Destructive Testing operations and contracts.

Hazards & Risks Covered

Hazard Risk Description
1. WHS Governance, Legal Compliance & Due Diligence
  • • Inadequate understanding of WHS Act 2011 and WHS Regulations as they relate to non-destructive testing (NDT), radiography, corrosion testing and magnetic particle / electromagnetic testing
  • • Lack of clear roles, responsibilities and accountability for WHS in NDT operations (PCBU, officers, workers, contractors)
  • • Failure of officers to exercise due diligence in relation to radiation safety, hazardous chemicals, confined spaces and plant used for NDT
  • • Weak WHS management system integration between client, principal contractor and NDT service provider
  • • Inadequate consultation, co-operation and co-ordination of activities between multiple PCBUs at shared worksites
  • • No formal review of WHS performance for NDT activities (audits, inspections, incident trends)
2. NDT Method Selection, Job Planning & Engineering Review
  • • Selection of inappropriate NDT method (e.g. radiography where ultrasonic or magnetic testing would provide lower risk and equivalent outcome)
  • • Inadequate engineering review of component design, access and materials leading to unsafe testing conditions
  • • Failure to consider interaction between strong magnetic fields, ferrous structures and other plant or medical implants
  • • Insufficient planning for work at height, inside confined spaces, in hazardous areas, or near pressurised systems during testing
  • • Commercial pressure driving unsafe timeframes or method selection without adequate risk assessment
3. Radiation Safety & Regulatory Control (Industrial Radiography)
  • • Uncontrolled exposure to ionising radiation from radiography sources or X-ray generators due to poor systems or supervision
  • • Inadequate licensing and registration of radiation sources, operators and premises as required under state/territory radiation laws
  • • Failure to establish and maintain effective exclusion zones and warning systems around radiography activities
  • • Loss, theft or misplacement of radioactive sources due to inadequate security arrangements and inventory control
  • • Inadequate monitoring of cumulative dose for radiation workers and absence of dosimetry program
  • • Poor emergency preparedness for radiation incidents, including source damage, stuck sources or unexpected exposure
4. Strong Magnetic Fields & Electromagnetic Testing Management
  • • Adverse interaction between strong magnetic fields and workers with pacemakers, implanted medical devices or metallic implants
  • • Attraction of loose ferromagnetic tools or components leading to impact or crush injuries near powerful magnets
  • • Interference with nearby electrical or electronic equipment (e.g. control systems, instrumentation) during magnetic particle and electromagnetic testing
  • • Inadequate demagnetisation processes leading to downstream hazards (e.g. lifting, machining, instrumentation malfunction)
  • • Uncontrolled exposure to strong magnetic fields due to poorly defined exclusion zones and access controls
5. Corrosion Testing & Materials Evaluation Systems
  • • Incorrect interpretation of corrosion or material testing results leading to unsafe plant remaining in service
  • • Lack of systematic inspection intervals for corrosion monitoring and wall thickness testing on critical equipment
  • • Poor traceability and record-keeping of corrosion data, locations and previous inspection outcomes
  • • Failure to integrate corrosion test results into asset integrity / maintenance management systems
  • • Use of incompatible or faulty testing equipment resulting in unreliable readings
  • • No structured peer review or verification process for high-consequence findings
6. Competency, Training & Certification of NDT Personnel
  • • NDT tasks performed by personnel without appropriate qualifications, certification or supervision (e.g. Level 1 working without Level 2 oversight)
  • • Insufficient training on WHS legislative duties, radiation safety, magnetic field hazards and corrosion testing principles
  • • Inadequate competency assessment for new technologies or methods (e.g. phased array, digital radiography)
  • • Training records not maintained or verified, leading to expired certifications or unrecognised gaps
  • • Language, literacy or cultural barriers impacting understanding of procedures and safety requirements
7. Plant, Equipment, Calibration & Maintenance Management
  • • Failure of NDT plant or equipment (e.g. radiography cameras, X-ray sets, magnetic yokes, UT units) due to inadequate maintenance systems
  • • Use of out-of-calibration instruments leading to incorrect results and unsafe asset decisions
  • • Lack of formal pre-use inspection and testing regimes for critical NDT equipment and accessories
  • • Use of non-conforming or damaged ancillary equipment (tripods, cables, lifting gear, ladders, scaffolds) during inspections
  • • Inadequate management of obsolete software, firmware or digital imaging systems impacting safety or data integrity
8. Work Environment, Site Access & Interface with Other Operations
  • • Uncontrolled interaction between NDT activities and concurrent operations (e.g. welding, hot work, crane lifts, process operations)
  • • Poor access to work areas leading to unsafe improvisation for positioning equipment or personnel
  • • Exposure to hazardous atmospheres (flammable, toxic, oxygen-deficient) during NDT in process plants or confined spaces
  • • Environmental extremes (heat, cold, wind, rain) adversely affecting NDT quality and worker safety
  • • Insufficient control of public or third-party access near mobile radiography, magnetic or corrosion testing operations (e.g. in workshops, laydown yards, wharves)
9. Contractor, Subcontractor & Client Interface Management
  • • Misalignment between client, principal contractor and NDT provider WHS expectations and standards
  • • Inadequate prequalification of subcontracted NDT providers, including radiation licences and equipment compliance
  • • Poor communication of site-specific risks, isolation status and emergency procedures to visiting NDT crews
  • • Lack of clarity over supervision, authority to stop work and incident reporting responsibilities for contractors
  • • Contractual arrangements that incentivise shortcuts or discourage reporting of safety concerns
10. Fatigue, Remote & After-Hours Work Management
  • • Fatigue-related errors in NDT interpretation or set-up, especially during night shifts or extended shifts
  • • Driving and travel risks to remote or offshore NDT locations without adequate journey management
  • • Working alone or in small teams in remote or isolated locations during radiography or magnetic testing
  • • Limited access to immediate medical or emergency response for NDT technicians at remote sites
  • • Pressure to continue work when fatigued due to schedule constraints or limited specialist personnel
11. Hazardous Chemicals, Consumables & Waste from NDT
  • • Exposure to hazardous chemicals from penetrant testing, developers, cleaners, corrosion inhibitors and etchants
  • • Inadequate labelling, storage and handling of chemical products and radiography processing chemicals (if used)
  • • Generation of hazardous waste (e.g. contaminated rags, chemical residues, lead screens) without appropriate disposal systems
  • • Chemical incompatibility incidents (e.g. mixing cleaners, use in confined or poorly ventilated areas)
  • • Lack of Safety Data Sheet (SDS) access and training specific to NDT consumables
12. Information Management, Reporting, Records & Data Integrity
  • • Loss or corruption of NDT records (radiographs, digital images, corrosion data) impacting future asset safety decisions
  • • Inadequate traceability between NDT reports, test locations, equipment and personnel
  • • Failure to report or analyse near misses, non-conformances and WHS incidents arising from NDT activities
  • • Unauthorised access or alteration of NDT results that could compromise plant integrity or regulatory compliance
  • • Poor document control leading to use of superseded procedures or techniques
13. Emergency Preparedness & Incident Management for NDT Activities
  • • Uncoordinated response to NDT-related emergencies such as radiation overexposure, chemical spills, falls from height or confined space incidents
  • • Lack of specific procedures for stuck radioactive sources, damaged X-ray equipment or loss of source containment
  • • Inadequate first aid and medical response capability for NDT-related injuries or exposures
  • • Poor post-incident investigation and learning processes, leading to recurrence of systemic failures
  • • Failure to notify regulators as required for notifiable incidents involving radiation or serious injury
14. Health Monitoring, Radiation Dose & Occupational Exposure Management
  • • Undetected long-term health impacts from chronic low-level ionising radiation exposure in radiography personnel
  • • Musculoskeletal disorders from repetitive manual handling of NDT equipment, awkward postures and work in confined spaces
  • • Inadequate health monitoring programs for workers exposed to radiation, noise, chemicals or strong magnetic fields
  • • Failure to recognise and manage individual sensitivity or medical restrictions related to radiation and magnetic fields
  • • Poor linkage between exposure data (dose records, noise monitoring, chemical use) and health monitoring outcomes

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
  • AS/NZS ISO 31000:2018: Risk management — Guidelines
  • AS/NZS ISO 45001:2018: Occupational health and safety management systems — Requirements with guidance for use
  • AS/NZS ISO 9712: Non-destructive testing — Qualification and certification of NDT personnel
  • AS/NZS 2243 series: Safety in laboratories — Guidance on radiation, chemicals and general laboratory safety where applicable to NDT environments
  • ARPANSA Codes & Guides (e.g. RPS series): Australian radiation protection and safety guidance for industrial radiography and occupational exposure
  • Safe Work Australia Codes of Practice: How to Manage Work Health and Safety Risks; Managing the Work Environment and Facilities; Hazardous Chemicals; Managing Noise and Preventing Hearing Loss at Work
  • AS/NZS 60079 & related standards: Explosive atmospheres — For NDT activities in hazardous areas
  • AS/NZS ISO/IEC 17025: General requirements for the competence of testing and calibration laboratories, where NDT laboratories are in scope
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

$79.5

Safe Work Australia Aligned