Product Overview

Summary: This Structural Retrofitting Procedures SOP provides a clear, step-by-step framework for planning and carrying out structural upgrades, strengthening and remedial works safely on Australian worksites. It integrates WHS requirements, engineering controls and construction best practice to protect workers, occupants and the public while preserving the structural integrity of existing buildings and infrastructure.

Structural retrofitting often involves intrusive work on ageing or compromised buildings, bridges and other structures, frequently in live environments where occupants, traffic and neighbouring properties must be protected. Unlike new builds, retrofits bring additional complexity: unknown structural conditions, concealed services, degraded materials, and the need to stage works so that stability is never compromised. This SOP sets out a structured, repeatable method for planning, sequencing and executing structural retrofitting activities in a way that prioritises safety, structural reliability and compliance with Australian WHS and building obligations.

The procedure covers the full lifecycle of a retrofit task, from initial structural assessment and risk identification through to temporary works design, isolation of services, controlled demolition, installation of new structural elements and final verification. It defines who does what—engineers, supervisors, contractors and WHS personnel—and embeds risk controls for hazards such as partial collapse, falling objects, exposure to hazardous materials, confined spaces, and working at heights. By implementing this SOP, organisations can reduce the likelihood of catastrophic failures, safeguard workers and building occupants, and demonstrate due diligence to regulators, clients and insurers when undertaking complex structural strengthening or remedial projects.

Key Benefits

• Ensure structural retrofitting works are planned and executed without compromising the stability of existing buildings or infrastructure.
• Reduce the risk of serious incidents such as structural collapse, falling objects and uncontrolled demolition during retrofit activities.
• Standardise communication and coordination between structural engineers, site supervisors and contractors for safer, more predictable outcomes.
• Demonstrate compliance with Australian WHS legislation, building regulations and relevant Australian Standards for structural work.
• Improve project efficiency by providing clear sequences, hold points and inspection requirements that minimise rework and delays.

Who is this for?

• Construction Project Managers
• Site Supervisors
• Structural Engineers
• WHS Managers
• Principal Contractors
• Building Maintenance Managers
• Civil Engineers
• Formwork and Steel Fixing Supervisors
• Remedial Builders
• Facilities Managers for Existing Buildings

Hazards Addressed

• Partial or progressive structural collapse during cutting, coring or demolition
• Falling objects from overhead work, drilling, coring or removal of structural elements
• Unstable temporary supports, propping or shoring failures
• Exposure to hazardous materials such as asbestos, lead-based paint or silica dust from concrete cutting
• Contact with live electrical or other services concealed in existing structures
• Working at heights on scaffolds, elevated work platforms or open edges
• Confined space risks in basements, service tunnels, pits or voids
• Noise, vibration and manual handling injuries associated with heavy tools and structural components
• Fire and explosion risks from hot works in or near existing structures
• Public and occupant safety risks in live or partially occupied buildings and adjacent public areas

Included Sections

• 1.0 Purpose and Scope
• 2.0 Definitions and Terminology (Retrofitting, Temporary Works, Propping, Live Load, etc.)
• 3.0 Roles, Responsibilities and Competency Requirements
• 4.0 Pre-Start Planning and Structural Assessment Requirements
• 5.0 Regulatory Approvals, Engineering Sign-off and Documentation
• 6.0 Hazard Identification and Risk Assessment for Retrofitting Activities
• 7.0 Temporary Works Design, Installation and Inspection (Propping, Shoring, Bracing)
• 8.0 Service Location, Isolation and Permit-to-Work Processes
• 9.0 Site Preparation, Exclusion Zones and Public/Occupant Protection
• 10.0 Required Plant, Equipment and Personal Protective Equipment (PPE)
• 11.0 Safe Work Methodology for Structural Cutting, Coring and Controlled Demolition
• 12.0 Safe Installation Procedures for New Structural Elements (Steel, Concrete, FRP, Post-Tensioning)
• 13.0 Working at Heights, Scaffolding and Access Systems Controls
• 14.0 Control of Hazardous Substances (Asbestos, Lead, Silica Dust, Hazardous Coatings)
• 15.0 Vibration, Noise and Manual Handling Risk Controls
• 16.0 Inspection, Testing, Hold Points and Engineering Verification
• 17.0 Emergency Preparedness and Response (Structural Instability, Collapse, Entrapment)
• 18.0 Communication, Toolbox Talks and Consultation with Workers
• 19.0 Handover, As-Built Documentation and Ongoing Monitoring Requirements
• 20.0 Recordkeeping, Review and Continuous Improvement of the SOP

Legislation & References

• Work Health and Safety Act 2011 (Cth) and corresponding state and territory WHS legislation
• Work Health and Safety Regulations 2011 (Cth) and state/territory equivalents
• Safe Work Australia – Model Code of Practice: Construction Work
• Safe Work Australia – Model Code of Practice: Managing the Risk of Falls at Workplaces
• Safe Work Australia – Model Code of Practice: How to Manage Work Health and Safety Risks
• AS/NZS 1170 series: Structural design actions
• AS 3600: Concrete structures
• AS 4100: Steel structures
• AS 3850: Prefabricated concrete elements
• AS 3610: Formwork for concrete
• AS/NZS 1576: Scaffolding
• AS/NZS 1891: Industrial fall-arrest systems and devices
• AS 2601: The demolition of structures
• National Construction Code (NCC) – Building Code of Australia (BCA)