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Scrap Metal Recycling Risk Assessment

This risk assessment covers scrap receival, sorting, processing, lifting, cutting, storage, maintenance and emergency activities.

Activities covered include

  • Manage site access, traffic movements and public interactions
  • Carry out cutting, hot work and manage ignition sources
  • Respond to maintenance issues, breakdowns and emergencies

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Scrap Metal Recycling 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

Product Overview

This risk assessment covers scrap receival, sorting, processing, lifting, cutting, storage, maintenance and emergency activities. It supports planning by identifying hazards from traffic, sharp materials, plant, hazardous substances and changing yard conditions.

Activities & Risks Covered

This assessment addresses activities and risks including:

  • Manage site access, traffic movements and public interactions
  • Receive and inspect scrap loads
  • Manually handle and sort scrap materials
  • Operate processing plant, conveyors and fixed machinery
  • Undertake mobile plant and lifting operations
  • Carry out cutting, hot work and manage ignition sources
  • Handle batteries, hazardous substances and contaminated scrap
  • Manage stockpiles, storage areas and housekeeping
  • Use electrical equipment and temporary power
  • Respond to maintenance issues, breakdowns and emergencies

Who is this for?

Suitable for contractors, workers, supervisors and businesses carrying out scrap metal recycling activities.

Activities & Hazards Covered

Activity Potential Hazards
Site access, traffic and public interface
  • Collision between forklifts, loaders, trucks and pedestrians
  • Reversing incidents in shared traffic areas
  • Unauthorised entry by visitors, drivers or scavengers
  • Poor visibility, blind corners and congestion around receival and stockpile areas
Receival and inspection of scrap loads
  • Unstable loads shifting during unloading
  • Hidden hazardous items such as gas cylinders, batteries, pressurised containers or chemical residues
  • Sharp edges, protrusions and ejected material during load release
  • Exposure to contaminated scrap, oils, dusts or unknown substances
Manual handling and sorting of scrap
  • Cuts, punctures and crush injuries from sharp or jagged metal
  • Musculoskeletal strain from lifting, dragging, pushing or awkward postures
  • Pinch points while separating bundled or tangled scrap
  • Eye injuries from flying fragments during manual breaking or trimming
Processing plant, conveyors and fixed machinery
  • Entanglement, drawing-in or crushing at conveyors, shears, balers, shredders and moving parts
  • Unexpected start-up during clearing jams, cleaning or maintenance
  • Ejected material, noise and vibration from processing equipment
  • Contact with unguarded nip points or damaged guards
Mobile plant and lifting operations
  • Plant rollover or collision during loading, pushing or stockpile work
  • Dropped loads from magnets, grabs, slings or forks
  • Workers struck by swinging loads or mobile attachments
  • Instability from uneven ground, overloading or poor stacking
Cutting, hot work and ignition sources
  • Fire or explosion from residual fuel, oils, sealed containers, gas cylinders or aerosols in scrap
  • Burns from sparks, hot metal and cutting equipment
  • Ignition of nearby combustible materials or waste
  • Exposure to metal fumes and smoke during thermal cutting
Hazardous substances, batteries and contaminated scrap
  • Exposure to acids, oils, fuels, heavy metal residues, refrigerants or other hazardous chemicals
  • Chemical burns, inhalation of fumes or dermatitis during handling
  • Fire from damaged lithium batteries or mixed battery storage
  • Environmental release from leaking containers or contaminated runoff
Stockpiling, storage and housekeeping
  • Collapse of unstable stacks or stockpiles
  • Slips, trips and falls on uneven ground, loose scrap, banding or fluids
  • Cuts and punctures while moving around storage areas
  • Fire spread through poorly managed combustible or reactive stock
Electrical equipment and temporary power
  • Electric shock from damaged leads, plugs, tools or wet conditions
  • Fire from faulty electrical equipment
  • Unauthorised repair or use of tagged unsafe equipment
  • Contact with live services during maintenance or relocation of plant
Maintenance, breakdown response and emergencies
  • Serious injury during fault finding, unjamming or emergency shutdowns
  • Exposure to stored energy, moving plant or hazardous atmospheres during maintenance
  • Delayed response to fire, injury, explosion or chemical release
  • Inadequate first aid or communication during incidents

Need to tailor this risk assessment?

Use the BlueSafe Portal to add site-specific activities, hazards, controls, responsibilities and review details before the assessment is put into use.

Acceptance Guaranteed: If your client or principal requests changes during document review, BlueSafe will help revise the document at no extra cost and support resubmission until it is accepted.

Legislation & References

The template records model guidance used to inform the documented controls. Applicable WHS/OHS laws and adopted Codes vary by state or territory, so confirm the current local requirements when tailoring the assessment:

  • Model guidance: Model Code of Practice: Managing electrical risks in the workplace — 2.1 Identifying the hazards; p. 14.
  • Model guidance: Model Code of Practice: Managing the work environment and facilities — 2. The work environment; p. 13.
  • Model guidance: Model Code of Practice: Managing risks of plant in the workplace — 4.1 Guarding plant; p. 39.
  • Model guidance: Model Code of Practice: Hazardous manual tasks — 4.1 The hierarchy of control measures; p. 31.
  • Model guidance: Model Code of Practice: First aid in the workplace — 3. First aid equipment, facilities and training; p. 12.
  • Model guidance: Model Code of Practice: How to manage work health and safety risks — 2. Step 1 — How to identify hazards; p. 12.
  • Model guidance: Model Code of Practice: Managing risks of hazardous chemicals in the workplace — 2.1 How to identify which chemicals are hazardous; p. 15.

Standard Risk Assessment Features (Click to Expand)
  • Activity-specific hazard identification and control measures
  • Initial and residual risk ratings
  • Assigned responsible persons for each activity
  • Risk matrix and assessment classification
  • Review, monitoring and sign-off fields
  • Site-specific customisation before use

Suitable for Industries

Transport and LogisticsManufacturing and ProductionWarehousing and DistributionMetal Fabrication and Welding

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