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Industrial Workshop Lifting Jacks and Hoists Risk Assessment

Industrial Workshop Lifting Jacks and Hoists Risk Assessment

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Industrial Workshop Lifting Jacks and Hoists Risk Assessment

Product Overview

Identify and control organisational risks associated with Industrial Workshop Lifting Jacks and Hoists through a structured, management-level WHS Risk Management framework. This Risk Assessment supports compliance with the WHS Act, demonstrates Due Diligence, and helps protect your business from operational and legal liability.

Risk Categories & Hazards Covered

This document assesses risks and outlines management controls for:

  • Governance, WHS Duties and Legal Compliance: Assessment of PCBU responsibilities, officer due diligence, consultation arrangements, and WHS governance structures for lifting operations.
  • Plant Selection, Design and Suitability: Management of procurement criteria, conformity with standards, load ratings, and suitability of jacks and hoists for intended industrial workshop tasks.
  • Installation, Commissioning and Layout of Hoists and Jacks: Evaluation of installation controls, structural adequacy, anchoring, clearances, and workshop layout to minimise collision and crush risks.
  • Inspection, Testing, Maintenance and Repair Systems: Systems for scheduled inspections, load testing, defect reporting, tagging-out, and maintenance record keeping for lifting plant.
  • Operator Competency, Licensing and Training Systems: Controls for competency assessment, licensing where required, induction, refresher training, and supervision of hoist and jack operators.
  • Procedures, Work Instructions and Safe Systems of Work: Development and implementation of documented procedures, work instructions, and permit systems for safe use of lifting equipment.
  • Load Management, Vehicle Positioning and Stability Controls: Management of load distribution, centre-of-gravity, vehicle placement, use of stands and supports, and controls to prevent collapse or tip-over.
  • Isolation, Lockout and Emergency Controls for Lifting Plant: Protocols for energy isolation, lockout/tagout, emergency stop devices, and prevention of unauthorised use of jacks and hoists.
  • Workshop Traffic Management and Interaction with Other Plant: Assessment of vehicle and pedestrian movements, interaction with forklifts and other plant, and traffic management planning around hoist bays.
  • Ergonomics, Manual Handling and Work Organisation: Controls for access to vehicles on hoists, work-at-height interfaces, body positioning, and manual handling associated with lifting tasks.
  • Contractor, Visitor and Third-Party Management: Systems for induction, supervision, access control, and coordination of contractors and visitors working around lifting equipment.
  • Incident Reporting, Monitoring and Continuous Improvement: Processes for reporting near misses and incidents, trend analysis, corrective actions, and periodic review of lifting plant risks.
  • Emergency Preparedness and Rescue Planning: Planning for vehicle collapse, entrapment, equipment failure, and integration with site emergency response and rescue procedures.
  • Environmental and Infrastructure Integrity: Assessment of floor strength, drainage, lighting, ventilation, and environmental conditions that may affect the safe operation of jacks and hoists.

Who is this for?

This Risk Assessment is designed for Business Owners, Workshop Managers, and Safety Professionals responsible for planning, approving, and overseeing Industrial Workshop Lifting Jacks and Hoists operations across their organisation.

Hazards & Risks Covered

Hazard Risk Description
1. Governance, WHS Duties and Legal Compliance
  • • Lack of clear allocation of WHS duties for lifting jacks and hoists under WHS Act 2011 and WHS Regulations
  • • Directors and senior management not exercising due diligence in relation to plant risks
  • • Failure to identify all relevant Australian Standards (e.g. AS 1418, AS 2550, AS 2615, AS 4991) and OEM requirements
  • • Absence of a documented plant risk register covering all types of jacks and hoists in the workshop
  • • Inadequate consultation with workers and HSRs on selection, use and maintenance of jacks and hoists
  • • No formal process to verify supplier / installer competence and compliance documentation
  • • Failure to ensure safe systems of work for use of floor jacks, mechanical hoists and vehicle support stands
  • • Inadequate review of incidents and near misses related to lifting systems at a governance level
2. Plant Selection, Design and Suitability
  • • Selection of jacks or hoists that are not rated or designed for the loads and vehicle types handled
  • • Use of domestic or non-industrial floor jacks in a heavy industrial workshop environment
  • • Incompatible lifting points or adaptor fittings leading to unstable load support
  • • Lack of design verification or registration where required for certain hoists
  • • Acquisition of plant without considering ergonomics, access, guarding and emergency features
  • • Failure to consider environmental conditions (corrosive, wet, outdoor) when selecting equipment
  • • Inadequate capacity margin between equipment WLL/SWL and maximum expected load
  • • No formal process to retire outdated, non-compliant or damaged jacks and hoists
3. Installation, Commissioning and Layout of Hoists and Jacks
  • • Incorrect hoist installation leading to structural failure or collapse
  • • Inadequate floor strength or anchorage for two-post and four-post hoists
  • • Poor workshop layout causing congestion, vehicle collision with hoist columns, and restricted access for emergency egress
  • • Insufficient overhead clearance resulting in contact between raised loads and roof structures or services
  • • Absence of commissioning tests and sign-off by a competent person
  • • Inadequate separation between hoists and pedestrian walkways or other plant
  • • Lack of clearly marked hoist operating zones and exclusion zones around lifted vehicles
  • • Hidden underground services affected by hoist anchors or floor-mounted jacks and rails
4. Inspection, Testing, Maintenance and Repair Systems
  • • Inadequate preventative maintenance leading to mechanical or hydraulic failure of jacks and hoists
  • • Failure to detect cracks, worn components, hydraulic leaks or faulty safety locks
  • • Lack of documented inspection regime for floor jacks, vehicle stands and lifting accessories
  • • Repairs performed by unqualified personnel using non-genuine parts
  • • No tagging or isolation system for defective lifting equipment
  • • Maintenance activities creating secondary hazards (e.g. working under unsupported loads)
  • • Out-of-date test certificates or missed periodic statutory inspections
  • • Reliance on user reporting only, without scheduled competent inspections
5. Operator Competency, Licensing and Training Systems
  • • Untrained personnel operating hoists and jacks
  • • Assumptions that automotive trade qualification alone is sufficient to operate specific lifting systems
  • • Inconsistent competency levels between shifts and sites
  • • No verification of competency for contractors or temporary staff
  • • Lack of refresher training leading to skill fade and unsafe shortcuts
  • • Inadequate understanding of load limits, lifting points and the difference between lifting and supporting
  • • Failure to train workers in emergency procedures for stuck or failed hoists
  • • Reliance on informal ‘buddy system’ training without structured assessment
6. Procedures, Work Instructions and Safe Systems of Work
  • • Absence of written procedures for the safe use of jacks, hoists and support stands
  • • Inconsistent work practices between technicians and shifts
  • • Failure to distinguish between temporary lifting and long-term support requirements
  • • Use of hoists or jacks outside of OEM-specified applications (e.g. side lifting on non-approved points)
  • • No documented controls for working alone when vehicles are raised
  • • Inadequate procedures for multi-hoist operations or split-level lifting of long vehicles
  • • Poor integration between high-level risk assessments and detailed SWMS, leading to procedural gaps
  • • Procedures not reviewed after incidents, modifications or regulatory changes
7. Load Management, Vehicle Positioning and Stability Controls
  • • Incorrect estimation of vehicle or component weight versus jack/hoist capacity
  • • Uneven load distribution causing vehicle instability on hoists or floor jacks
  • • Failure to secure vehicles (brakes, chocks) leading to rolling or shifting on hoists
  • • Use of improvised packing or non-rated blocks between jack saddles and load
  • • Incorrect axle or chassis lifting points leading to structural damage and collapse risk
  • • Lifting of modified or heavily loaded vehicles without adjusted load and balance assessment
  • • No formal system for managing centre-of-gravity issues on vehicles with major components removed
  • • Simultaneous tasks on the same raised vehicle causing unexpected movement or imbalance
8. Isolation, Lockout and Emergency Controls for Lifting Plant
  • • Unexpected lowering or movement of hoists during work under raised vehicles
  • • Unauthorised operation of hoists or jacks while others are working underneath
  • • Failure to isolate power during maintenance or when hoists are tagged out
  • • Inadequate or non-functional emergency stop and safety lock systems
  • • No formal procedure for controlled lowering of stuck or failed hoists
  • • Lack of redundancy in support (reliance on hydraulic pressure alone)
  • • Confusion over responsibility for isolating and re-energising hoists
  • • Inadequate signage and lockout devices leading to inadvertent re-use of defective plant
9. Workshop Traffic Management and Interaction with Other Plant
  • • Vehicle collisions with hoist columns, jacks, or raised vehicles during manoeuvring
  • • Forklifts or mobile plant contacting hoists, floor jacks or loads being raised
  • • Pedestrians entering hoist operating zones without awareness of lift status
  • • Restricted visibility around hoist bays, leading to near misses or contact incidents
  • • Lack of segregation between parking, queuing and lifting areas
  • • Uncontrolled reversing of vehicles into hoist bays without spotter systems
  • • Use of jacks on unsuitable or cluttered floor surfaces leading to sudden movement
  • • Emergency access routes obstructed by vehicles waiting for hoist access or jack use
10. Ergonomics, Manual Handling and Work Organisation
  • • Awkward postures and excessive force when positioning floor jacks and mechanical hoists arms
  • • Manual handling of heavy jack units, stands or adaptors without mechanical assistance
  • • Repetitive movements leading to musculoskeletal disorders for technicians frequently using jacks and hoists
  • • Time pressure and poor work scheduling prompting shortcuts in lift set-up and stability checks
  • • Insufficient staffing levels leading to solo handling of tasks designed for two persons
  • • Inadequate lighting around hoist bays, increasing risk of misplacement of jacks or stands
  • • Fatigue-related errors in judgement when assessing load stability late in shifts
  • • Poorly designed controls or displays leading to operator strain or mis-readings
11. Contractor, Visitor and Third-Party Management
  • • Contractor technicians using workshop hoists and jacks without understanding site-specific controls
  • • Service providers bypassing isolation and lockout procedures during maintenance work
  • • Visitors entering hoist bays or areas where jacks are in use without supervision
  • • Inconsistent safety standards between host employer and contractors leading to confusion and unsafe practices
  • • Lack of clarity about who controls lifting operations when multiple parties are involved
  • • Inadequate exchange of plant condition and defect information between owners and contractors
  • • Subcontractors bringing non-compliant or poorly maintained portable jacks and lifting devices on site
12. Incident Reporting, Monitoring and Continuous Improvement
  • • Under-reporting of near misses involving hoists, jacks and falling loads
  • • Repeat incidents due to poor investigation and follow-up of root causes
  • • Lack of trend analysis masking systemic issues with lifting practices or equipment
  • • No feedback loop from incidents to training, procedures or equipment selection
  • • Supervisors normalising deviance from safe systems due to production pressure
  • • Workers not understanding the importance of reporting minor defects or anomalies with lifting plant
  • • Failure to share critical safety learnings between different sites or workshops
13. Emergency Preparedness and Rescue Planning
  • • Delayed response to hoist collapse or vehicle instability incidents
  • • Workers trapped under or between vehicles and plant without a rehearsed rescue plan
  • • Emergency services unable to access hoist bays due to poor layout or blocked access routes
  • • Lack of suitable equipment to safely support or stabilise vehicles during rescue
  • • Workers not trained in first response actions for hydraulic failures or suspended loads
  • • Confusion over who coordinates emergency response within the workshop
  • • Inadequate post-incident scene preservation for investigation
14. Environmental and Infrastructure Integrity
  • • Degradation of floor surfaces leading to uneven support for floor jacks and vehicle stands
  • • Corrosion of hoists, anchors or structural elements in wet or chemically aggressive environments
  • • Inadequate drainage causing pooling of liquids under hoists and jacks, increasing slip and stability risks
  • • Power outages or electrical faults causing uncontrolled stoppage of hoists in raised position
  • • Poor ventilation in enclosed hoist bays leading to accumulation of fumes during under-vehicle work
  • • Insufficient load rating of mezzanines or pits used in conjunction with jacks and hoists
  • • Infrastructure modifications (trenching, new services) undermining slab integrity around hoists

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
  • Safe Work Australia – Managing the Risks of Plant in the Workplace Code of Practice: Guidance on lifecycle management of plant, including jacks and hoists.
  • Safe Work Australia – Hazardous Manual Tasks Code of Practice: Guidance on managing musculoskeletal risks associated with workshop lifting activities.
  • Safe Work Australia – Managing Risks in Stevedoring and Vehicle Loading/Unloading (where applicable): Principles relevant to load stability and vehicle positioning.
  • AS 2550 series (Cranes, Hoists and Winches – Safe Use): General principles for the safe use, inspection, and maintenance of hoists and related lifting equipment.
  • AS 1418 series (Cranes, Hoists and Winches – Design and Construction): Technical requirements for the design and rated capacity of lifting plant.
  • AS/NZS 4801 / ISO 45001: Occupational health and safety management systems – requirements for systematic WHS governance and continuous improvement.
  • AS 3990 / AS 4100 (where applicable): Structural integrity and steelwork design considerations for supporting structures and floor systems.
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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