Product Overview

Summary: This Sheet Metal Bending Safe Operating Procedure sets out a clear, step-by-step method for safely operating press brakes, pan brakes, folders and other bending equipment in Australian workplaces. It helps you control crush, amputation and manual handling risks while lifting productivity and demonstrating compliance with WHS duties and industry standards.

Sheet metal bending is a core activity in fabrication workshops, HVAC manufacturing, roofing, vehicle body building and general engineering. Yet the combination of powerful press brakes, moving tooling, sharp edges and repetitive handling creates a high potential for serious crush and amputation injuries, musculoskeletal disorders and eye injuries. This Sheet Metal Bending Safe Operating Procedure provides a practical, workshop-ready framework for completing bending tasks safely and consistently, whether you are working with manual folders or CNC press brakes.

The SOP walks your team through each stage of the bending process – from pre-start inspections, tooling setup and job planning through to safe operation, adjustment, jam clearing and shutdown. It embeds WHS risk management into everyday work by specifying guarding requirements, use of light curtains and two-hand controls, correct PPE, safe lifting techniques and communication between operators and assistants. By implementing this SOP, businesses can reduce incident rates, improve operator confidence, standardise training for apprentices and new starters, and provide documented evidence of safe systems of work in line with Australian WHS legislation and applicable standards.

Key Benefits

• Reduce the risk of crush, pinch and amputation injuries around press brakes and folding equipment.
• Ensure consistent, compliant setup and operation of sheet metal bending machinery across all shifts and operators.
• Improve productivity by minimising rework, tooling damage and unplanned downtime due to unsafe or incorrect use.
• Support WHS compliance by documenting a clear safe system of work aligned with Australian legislation and standards.
• Strengthen induction and refresher training with a structured, step-by-step reference for operators and apprentices.

Who is this for?

• Sheet Metal Workers
• Fabrication Tradespersons
• Boilermakers
• Workshop Supervisors
• Production Managers
• WHS Advisors and HSE Coordinators
• Engineering Managers
• Apprentice Coordinators and Trainers
• Maintenance Supervisors
• Manufacturing Business Owners

Hazards Addressed

• Crush and amputation injuries from moving rams, dies and clamping mechanisms
• Pinch points between sheets, fingers, tooling and machine frames
• Strains and sprains from manual handling of heavy or awkward sheet metal
• Eye injuries from flying metal particles, burrs and offcuts
• Cuts and lacerations from sharp sheet metal edges and corners
• Entanglement in moving parts, tooling or workpieces
• Impact injuries from unexpected sheet movement or spring-back
• Noise exposure from repeated bending operations in enclosed workshops
• Electrical hazards associated with powered bending equipment
• Slips, trips and falls due to offcuts, scrap and tools on the workshop floor

Included Sections

• 1.0 Purpose and Scope
• 2.0 Definitions and Equipment Types (press brakes, pan brakes, folders, CNC vs manual)
• 3.0 Roles, Responsibilities and Competency Requirements
• 4.0 Applicable Legislation, Standards and Codes of Practice
• 5.0 Required PPE and Safety Equipment
• 6.0 Pre-Start Inspections and Machine Guarding Checks
• 7.0 Job Planning, Material Handling and Work Area Setup
• 8.0 Tooling Selection, Installation and Alignment
• 9.0 Safe Operating Procedure – Manual Bending Equipment
• 10.0 Safe Operating Procedure – CNC and Hydraulic Press Brakes
• 11.0 Use of Guards, Light Curtains, Two-Hand Controls and Interlocks
• 12.0 Manual Handling, Team Lifting and Use of Mechanical Aids
• 13.0 Managing Sharp Edges, Burrs and Offcuts
• 14.0 Clearing Jams, Misfeeds and Faults Safely (Lockout/Tagout)
• 15.0 Quality Checks, Dimensional Verification and Rework Controls
• 16.0 Shutdown, Isolation and Housekeeping Requirements
• 17.0 Hazard Identification, Risk Assessment and Control Measures
• 18.0 Emergency Procedures and Incident Response
• 19.0 Training, Induction and Competency Assessment Records
• 20.0 Inspection, Maintenance and SOP Review Schedule

Legislation & References

• Model Work Health and Safety Act and Regulations (as implemented in each state and territory)
• Safe Work Australia – Code of Practice: Managing risks of plant in the workplace
• Safe Work Australia – Code of Practice: Managing the risk of falls at workplaces (for elevated bending stations or platforms)
• AS 4024 series: Safety of machinery
• AS/NZS 4801: Occupational health and safety management systems (superseded but still commonly referenced)
• ISO 45001: Occupational health and safety management systems (where adopted by the business)
• AS/NZS 2161 series: Occupational protective gloves
• AS/NZS 1337.1: Personal eye protection
• AS/NZS 1269 series: Occupational noise management