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Metalworking Rolling and Wire Machinery Risk Assessment

Metalworking Rolling and Wire Machinery Risk Assessment

  • • 100% Compliant with Australian WHS Acts & Regulations
  • • Fully Editable MS Word & PDF Formats Included
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  • • Includes 2 Years of Free Compliance Updates

Metalworking Rolling and Wire Machinery Risk Assessment

Product Overview

Identify and control organisational risks associated with Metalworking Rolling and Wire Machinery through a structured, management-level WHS Risk Management approach that focuses on governance, planning, plant lifecycle and systems of work. This Risk Assessment supports compliance with the Work Health and Safety Act and Regulations, helping to demonstrate Due Diligence and reduce operational and legal exposure for your business.

Risk Categories & Hazards Covered

This document assesses risks and outlines management controls for:

  • WHS Governance, Consultation and Legal Compliance: Assessment of senior management duties, consultation arrangements, officer due diligence, and alignment of site systems with statutory WHS obligations.
  • Plant Procurement, Design and Integration (All Metal Rolling and Wire Machinery): Management of specification, supplier selection, CE/AS compliance, integration into existing lines, and lifecycle risk considerations before equipment is brought to site.
  • Guarding, Interlocks and Physical Safeguarding Systems: Evaluation of fixed and interlocked guards, nip-point protection, emergency stop devices, light curtains and safety distance calculations for rolling and wire machinery.
  • Control Systems, Automation and High‑Speed Wire Dynamics: Assessment of safety-related control systems, PLC and automation logic, speed control, run‑down times, and the risks of wire recoil, breakage and entanglement.
  • Plant Layout, Traffic Management and Exclusion Zones: Management of machinery positioning, access ways, pedestrian/plant interaction, coil storage areas, exclusion zones and line‑of‑sight for operators and spotters.
  • Coil, Strip and Wire Handling Systems (Mechanical and Manual): Evaluation of decoilers, recoilers, pay‑off reels, cranes, forklifts, trolleys and manual handling practices for coils, strip and wire packs.
  • Maintenance, Inspection and Asset Management of Plant: Systems for preventive maintenance, statutory inspections, condition monitoring, defect reporting and end‑of‑life replacement planning for rolling and wire machinery.
  • Isolation, Lockout/Tagout and Access for Cleaning, Setup and Fault Clearing: Protocols for energy isolation, verification of zero energy, safe access into danger zones, jam clearing, cleaning, die and roll changes, and setup adjustments.
  • Competency, Training and Supervision of Operators and Setters: Assessment of role‑specific competency requirements, induction, refresher training, supervision levels and authorisation to operate or set up machinery.
  • Hazardous Chemicals, Fumes, Dusts and Thermal Risks: Management of lubricants, coolants, coatings, welding or cutting by‑products, airborne contaminants, hot surfaces and burn/scald risks associated with rolling operations.
  • Noise, Vibration and Fatigue Management: Evaluation of exposure to continuous and impact noise, hand‑arm and whole‑body vibration, shift patterns and fatigue risks in high‑demand production environments.
  • Electrical, Pneumatic and Hydraulic Energy Safety: Assessment of electrical distribution, control panels, pneumatic and hydraulic circuits, stored energy, pressure systems and verification of isolation points.
  • Emergency Preparedness, Incident Response and First Aid: Planning for emergency stops, entanglement response, fire, mechanical failure, rescue procedures, first aid capability and post‑incident investigation.
  • Contractor, Visitor and Supplier Management: Controls for contractor induction, permits to work, supervision, OEM service personnel, delivery drivers and visitor access around operational machinery.
  • Documentation, Procedures and Change Management: Governance of SOPs, work instructions, risk registers, permits, version control and formal management of change for plant modifications and process improvements.

Who is this for?

This Risk Assessment is designed for Business Owners, Operations Managers, Engineering Managers and Safety Professionals responsible for planning, procuring and managing metalworking rolling and wire machinery operations across their organisation.

Hazards & Risks Covered

Hazard Risk Description
1. WHS Governance, Consultation and Legal Compliance
  • • Lack of an overarching WHS management system specific to metal rolling, wire and coiling machinery operations
  • • Inadequate understanding of PCBU duties under WHS Act 2011 and WHS Regulation for plant and high‑risk work
  • • Insufficient consultation with workers, Health and Safety Representatives (HSRs) and contractors about machinery risks and changes
  • • No formal process to review incidents, near misses and audit findings and translate them into system improvements
  • • Inadequate resourcing (time, budget, competent people) for safe design, procurement, maintenance and training
  • • Poor integration of WHS requirements into business planning, production targets and KPIs
  • • Failure to verify compliance of suppliers, installers and maintenance contractors with WHS obligations
2. Plant Procurement, Design and Integration (All Metal Rolling and Wire Machinery)
  • • Selection of machinery that does not comply with Australian Standards or is not fit for intended use (e.g. imported rolling mills or wire drawing machines lacking appropriate guarding or emergency stops)
  • • Poor design integration of decoilers, strip winders, coil winding stations and shuttle coiling systems leading to entanglement, crush and nip point exposures
  • • Inadequate consideration of metal 3D printer, sputtering and high‑speed wire equipment hazards during design (e.g. fumes, lasers, high voltage, moving parts)
  • • Failure to obtain or review manufacturer’s instructions, conformity documentation and safe operating parameters
  • • Insufficient consideration of ergonomic factors (feed height, coil handling, roll change‑out, maintenance access)
  • • Lack of engineered segregation between high‑speed moving wires, rotating rolls and pedestrian/vehicle routes
  • • No formal verification and commissioning process for new or modified plant and associated controls
3. Guarding, Interlocks and Physical Safeguarding Systems
  • • Inadequate guarding of nip points, in‑running rollers, chain drives, feed rolls and rotating shafts on rolling mills, wire drawing, chain making and spring forming machines
  • • Defeatable or bypassed interlock systems on doors, hoods, shuttle coiling covers and mesh weaving machine guards
  • • Poorly designed or maintained light curtains and safety sensors around high‑speed wires and automatic strip winders
  • • Guarding removed or modified during maintenance or setup without formal risk assessment or re‑validation
  • • Insufficient distance between detection devices (light curtains, mats) and danger zones, allowing contact before machine stops
  • • Failure of emergency stop devices (e‑stops not accessible, not functional, not tested)
  • • Use of temporary, makeshift or damaged guards (e.g. mesh panels cable‑tied, missing fasteners)
4. Control Systems, Automation and High‑Speed Wire Dynamics
  • • Malfunction or failure of programmable logic controllers (PLCs), safety relays or variable speed drives leading to unexpected start‑up, continuous run‑on or uncontrolled acceleration of rolls and wires
  • • Inadequate safety‑related control system design for decelerating high‑speed wires, roll formers and strip winders during fault conditions
  • • Lack of controlled start‑up and restart logic after emergency stops, jams or power interruptions
  • • Poor integration between decoiler tension controls, coiling devices and downstream equipment, causing sudden tension release (whiplash) of wires or coiled strip
  • • Software changes or program uploads made without verification, validation and change control documentation
  • • Defective or incorrectly configured sensors (tension sensors, limit switches, encoders, over‑speed detectors) on winding and drawing lines
  • • Insufficient alarm management, leading to alarm floods, ignored warnings or disabled alarms
5. Plant Layout, Traffic Management and Exclusion Zones
  • • Congested layouts around rolling mills, decoilers, strip winders, coil shuttles and mesh weaving machines creating crush and entanglement risks
  • • Uncontrolled interaction between pedestrians, forklifts and coil handling equipment when moving large coils, feed spools and rolls
  • • Inadequate demarcation of exclusion zones around high‑speed wires, rotating rolls, coiling shuttles and metal sputtering or 3D printing cells
  • • Poor visibility and lighting in coil loading, decoiling and roll change‑out areas
  • • Lack of safe access (platforms, stairs, walkways) resulting in climbing on plant or coils
  • • Emergency exits and e‑stop access obstructed by stored materials, coils or waste bins
6. Coil, Strip and Wire Handling Systems (Mechanical and Manual)
  • • Excessive manual handling of heavy coils, feed spools, rolls and die components leading to musculoskeletal disorders
  • • Uncontrolled movement, tipping or collapse of standing coils, stacked spools or strip packs
  • • Use of unsuitable lifting equipment or attachments (improvised hooks, slings, coil grabs) for loading decoilers and strip winders
  • • Inadequate systems for handling long, flexible and high‑tension wires or strip, resulting in whipping and lashing injuries
  • • Poorly planned roll and die change processes requiring awkward postures and pinch‑point contact
  • • Inadequate inspection and maintenance of cranes, hoists, forklifts and coil lifters
7. Maintenance, Inspection and Asset Management of Plant
  • • Breakdown of rolling mills, wire drawing and chain making machines due to inadequate preventative maintenance, leading to mechanical failures and increased injury risk
  • • Operating with worn or damaged components (rolls, dies, guides, bearings, guards) that compromise safety and product quality
  • • Unplanned downtime prompting unsafe shortcuts, bypassed interlocks or rushed maintenance
  • • Incomplete or inaccurate maintenance records hindering risk assessment and decision‑making
  • • Failure to identify developing defects in safety‑critical components (brakes, clutches, guarding, emergency stops, tension systems)
  • • Reliance on third‑party service providers without adequate WHS oversight
8. Isolation, Lockout/Tagout and Access for Cleaning, Setup and Fault Clearing
  • • Inadequate isolation procedures leading to unexpected energisation or movement of rolls, wires, coils or dies during cleaning, thread‑up, jam clearing or adjustment
  • • Use of informal practices (e.g. relying on emergency stop only) instead of full isolation for intervention within danger zones
  • • Multiple energy sources (electrical, pneumatic, hydraulic, stored mechanical tension, gravity) not all isolated and dissipated
  • • Lack of standardised lockout/tagout equipment and absence of group lock arrangements for multi‑person tasks
  • • Inadequate visual confirmation of isolation points and status on complex plant lines
  • • Contractors and short‑term workers not fully integrated into site isolation systems
9. Competency, Training and Supervision of Operators and Setters
  • • Operators and setters of rolling mills, chain making, spring forming, mesh weaving, wire drawing and 3D metal printing equipment lacking formal competency
  • • Over‑reliance on informal on‑the‑job learning without structured training or assessment, leading to unsafe habits
  • • Insufficient understanding of system‑level risks (e.g. tension control, wire dynamics, decoiler hazards) and consequences of parameter changes
  • • Inadequate supervision, particularly on night shift, weekends and during high‑production campaigns
  • • Failure to provide refresher training after plant modifications, incidents or procedure changes
  • • Language, literacy or numeracy barriers affecting understanding of procedures, signs and controls
10. Hazardous Chemicals, Fumes, Dusts and Thermal Risks
  • • Exposure to metal fumes, dusts and vapours from metal 3D printers, metal sputtering operations, strip processing and lubrication systems
  • • Use of flammable or combustible solvents, coolants and cleaning agents without adequate controls
  • • Inadequate ventilation or extraction on enclosed coil winding, wire drawing and roll forming operations where oils and lubricants are atomised
  • • Accumulation of fine metal dusts in enclosures and ducts creating fire and explosion risks
  • • Thermal burns from hot strip, coils, rolls, dies and components exiting process lines or post‑heat treatment
  • • Incorrect storage, labelling and segregation of hazardous chemicals used in cleaning, coating or 3D printing support processes
11. Noise, Vibration and Fatigue Management
  • • Prolonged exposure to high noise levels from rolling mills, wire drawing blocks, mesh weaving looms, strip winders and chain making machines
  • • Hand‑arm and whole‑body vibration exposure from vibrating plant, grinders and percussive tools used in die and roll maintenance
  • • Extended shifts and monotonous monitoring tasks around automated lines contributing to fatigue and reduced vigilance
  • • Inadequate break schedules and work‑rotation in noisy, high‑concentration areas
  • • Failure to conduct baseline and periodic audiometric testing where required by legislation
12. Electrical, Pneumatic and Hydraulic Energy Safety
  • • Non‑compliant electrical installations on rolling mills, wire drawing machines, mesh looms, decoilers and 3D printers
  • • Exposed live parts or damaged cables creating electric shock or arc flash risks
  • • Uncontrolled release of pneumatic or hydraulic energy in clamping, tensioning and coiling systems
  • • Inadequate earthing and bonding of metal equipment, wire paths and 3D printers leading to static discharge or shock risks
  • • Lack of periodic inspection and testing of electrical and fluid power systems
  • • Unclear responsibilities between site and OEM contractors for electrical safety of supplied equipment
13. Emergency Preparedness, Incident Response and First Aid
  • • Delayed or ineffective response to entanglement, crush or amputation incidents on rolling and wire machinery
  • • Lack of clear emergency stop, isolation and rescue protocols for coil winding shuttles, high‑speed wires and enclosed 3D printing or sputtering cells
  • • Insufficient first aid resources and training for lacerations, amputations, burns, eye injuries and crush trauma
  • • Poor communication processes during emergencies, particularly in noisy production areas
  • • Inadequate planning for fire, explosion or release events related to metal dusts, flammable chemicals and electrical faults
14. Contractor, Visitor and Supplier Management
  • • Contractors performing installation, maintenance or commissioning on rolling, coiling, wire drawing and 3D printing equipment without adequate knowledge of site‑specific hazards and procedures
  • • Inconsistent WHS standards between PCBU and contractors leading to gaps in control measures (e.g. isolation, guarding, working at height around plant)
  • • Visitors and suppliers inadvertently entering exclusion zones or interfering with plant operations
  • • Concurrent work activities (e.g. construction, electrical work, plant modifications) creating additional plant interaction risks
15. Documentation, Procedures and Change Management
  • • Outdated or inconsistent procedures for operating, setting, cleaning and maintaining metal rolling and wire machinery
  • • Uncontrolled changes to plant, software, materials or production speeds without formal risk assessment (management of change failure)
  • • Poor version control leading to multiple conflicting instructions in circulation
  • • Insufficient documentation of non‑routine tasks (e.g. major overhauls, die changes, commissioning of new lines)
  • • Reliance on key individuals’ knowledge without capturing critical information in structured documents
16. Monitoring, Audit, Health Surveillance and Continuous Improvement
  • • Failure to detect emerging risks from changes in production volumes, material types (e.g. new alloys, wire gauges) or technology (new 3D printers or sputtering units)
  • • Lack of systematic monitoring of leading and lagging WHS indicators related to plant safety
  • • Under‑reporting of near misses and minor incidents around machinery, preventing learning and improvement
  • • No health surveillance for workers exposed to noise, vibration, hazardous substances or repetitive manual handling
  • • Infrequent or superficial WHS audits of plant systems, allowing deterioration of controls

Need to add specific hazards for your workplace?

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Legislation & References

This document was researched and developed to align with:

  • Work Health and Safety Act 2011
  • Work Health and Safety Regulations 2017
  • Model Code of Practice – Managing Risks of Plant in the Workplace: Guidance on identifying, assessing and controlling risks associated with plant.
  • Model Code of Practice – How to Manage Work Health and Safety Risks: Framework for systematic hazard identification, risk assessment and control.
  • Model Code of Practice – Managing Noise and Preventing Hearing Loss at Work: Requirements and guidance for controlling noise from metalworking machinery.
  • Model Code of Practice – Hazardous Chemicals: Management of chemical hazards including lubricants, coolants and surface treatments.
  • AS/NZS ISO 31000:2018: Risk management — Guidelines
  • AS 4024 series – Safety of Machinery: Australian adoption of ISO machinery safety standards covering guarding, interlocks and control systems.
  • AS/NZS 4801 / ISO 45001: Occupational health and safety management systems — requirements for systematic WHS governance.
  • AS/NZS 3000 (Wiring Rules): Electrical installation requirements relevant to fixed and connected machinery.
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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