Plant and Equipment Safety Checklist

Quick answer: Plant and equipment must be guarded, maintained, registered (if required), operated only by competent persons, and subject to documented pre-start checks before every shift. This checklist steps through each obligation so nothing is missed.

Last reviewed: June 2026 by the BlueSafe Technical Team. Reflects current Model WHS Regulations.

Plant and equipment is one of the most significant sources of serious injury and fatality in Australian workplaces. Under the Model WHS Regulations (and equivalent state legislation), PCBUs have specific, enforceable duties to manage risks from plant — including duties around design, registration, maintenance, guarding, and operator competency.

Use this checklist as a practical day-to-day reference. Work through each section and address any items that cannot be ticked before putting the plant into operation.

1. Guarding and Physical Safeguards

Guarding prevents contact with dangerous parts of plant — moving parts, cutting edges, nip points, and hot surfaces.

• All dangerous moving parts (gears, belts, shafts, blades) are fully guarded.
• Guards are securely fixed and cannot be easily removed without a tool.
• Guards have not been bypassed, removed, or modified since the last inspection.
• Adequate clearance exists around the plant to prevent unintended contact.
• Warning signs and safety labels are in place, legible, and not faded.
• Light curtains, two-hand controls, or interlocks (where required) are functional.

2. Emergency Stop and Safety Devices

Emergency stops and safety devices must work every time, without exception.

• Emergency stop buttons/switches are clearly identified (red on yellow), unobstructed, and within easy reach of the operator.
• Emergency stops have been tested and confirmed functional.
• Safety interlocks (e.g. door guards, limit switches) operate correctly.
• Braking systems engage and hold load as designed.
• Pressure relief valves, overload protection, and thermal cut-outs are in place and serviceable.

3. Registration of Registrable Plant

Certain high-risk plant must be registered with the state WHS regulator before it is used. Operating unregistered registrable plant is a serious breach.

• Plant has been identified against Schedule 5 of the WHS Regulations (or state equivalent) to determine whether it is registrable.
• Where registration is required, a current registration certificate is held on site and available for inspection.
• Design registration (where required) was obtained prior to manufacture or import.
• Registration renewals are tracked and completed before expiry.
• The plant's registration number is marked on the plant as required.

For a structured way to track all plant items and their registration status, see our guide on what is a plant and equipment register.

4. Maintenance and Servicing

Maintenance must be planned, documented, and carried out by competent persons.

• A maintenance schedule exists for this plant, based on manufacturer specifications and regulatory requirements.
• The plant is within its current service interval — no overdue maintenance items.
• Maintenance records (service history, inspections, repairs) are documented and readily accessible.
• Maintenance is performed by a competent person (qualified tradesperson or licensed certifier where required).
• Fluid levels (oil, hydraulic, coolant) have been checked and are within specification.
• No leaks, unusual noises, excessive vibration, or warning lights are present.
• Any manufacturer-specified consumable parts (filters, belts, blades) have been replaced at the correct intervals.

5. Pre-Start Checks

A pre-start check must be completed at the start of every shift before the plant is operated.

• A pre-start checklist exists for this item of plant.
• The pre-start check has been completed and signed off by the operator for today's shift.
• No defects, faults, or concerns were identified during the pre-start check.
• Where defects were identified, they have been recorded and the plant has been removed from service or repaired before use.
• Pre-start check records are retained as required.

Our guide on what is a plant pre-start checklist explains what these records must contain and how long they should be kept.

6. Operator Licences and Competency

Only persons who are competent — and licensed where required — may operate plant.

• A High Risk Work (HRW) licence is held by the operator for any plant that requires one (e.g. forklift, crane, elevating work platform, dogging, rigging).
• HRW licence class matches the specific plant being operated (e.g. LF for forklift, C6 for boom-type EWP).
• Licence expiry dates have been checked and are current.
• For plant not requiring an HRW licence, the operator has documented training or a record of demonstrated competency.
• Operator competency records are held in the plant and equipment register or personnel file.
• Young or inexperienced workers are supervised and are not operating plant unsupervised beyond their demonstrated competency.

7. Isolation and Lockout / Tagout Procedures

Before maintenance, repair, or clearing blockages, the plant must be isolated from all energy sources.

• A documented isolation procedure (lockout/tagout) exists for this plant.
• All energy sources are identified — electrical, pneumatic, hydraulic, gravity, stored mechanical energy.
• Isolation locks and personal danger tags are available and used correctly.
• No person performs maintenance or repair on plant that has not been isolated and locked out.
• Where multiple workers are involved, each worker applies their own personal lock.
• Isolation procedures are included in operator training and induction.

8. Fit for Purpose

Plant must be used only for the purpose for which it was designed and rated.

• The plant is being used within its design parameters and rated capacity.
• No modifications have been made to the plant without engineering approval and, where required, a new design registration.
• Attachments and accessories are rated and approved for use with this plant.
• Operating environment is suitable — ground conditions, overhead clearances, slope limits, and load ratings are within specification.
• Plant is not being used to substitute for a different class of plant (e.g. using a forklift as a work platform without an approved work platform attachment).

9. Defect Tagging and Out-of-Service Procedures

When plant is defective, it must be taken out of service immediately and clearly tagged.

• Out-of-service tags are available at the worksite.
• Any operator who identifies a defect knows to stop the plant and attach an out-of-service tag immediately.
• Defects are recorded in the plant register and reported to the supervisor.
• Defective plant is not operated until the defect is repaired and cleared by a competent person.
• Repairs to defective plant are documented in the service history.

10. Manuals, Documentation, and Signage

Operators must have access to the information they need to use plant safely.

• The operator's manual for this plant is available on site (hard copy or accessible digital copy).
• The manual is in English (or the operator's language if required for safe operation).
• Load rating plates, capacity markings, and operating instructions are affixed to the plant and legible.
• Emergency procedures (including emergency stop locations) are communicated to all operators.
• The plant is listed in the site's plant and equipment register with current details including registration status, maintenance schedule, and responsible person.

State and Territory Variations

This checklist is based on the Model WHS Regulations published by Safe Work Australia. Most states and territories have adopted these regulations, with some variations.

Always verify the current requirements with your state or territory regulator — registration thresholds, licence classes, and mandatory inspection intervals may vary.

Related guides

• What Is a Plant and Equipment Register?
• What Is a Plant Pre-Start Checklist?
• Notifiable Incidents: What Must Be Reported to SafeWork
• How to Write a Safe Work Method Statement (SWMS)

Frequently asked questions

What is considered 'plant' under the WHS Regulations?

Under the Model WHS Regulations, 'plant' includes any machinery, equipment, appliance, container, implement, or tool — and any component or fitting. This covers everything from forklifts and cranes to woodworking machinery, pressure vessels, and scaffolding.

Which plant must be registered under the WHS Regulations?

Schedule 5 of the Model WHS Regulations lists 'registrable plant' that must be registered with the relevant state regulator before use. Common examples include tower cranes, mobile cranes over 10 tonnes, pressure vessels, amusement devices, and certain lifts. Design registration may also be required before manufacture.

Who is responsible for plant and equipment safety?

Responsibility sits with whoever manages or controls the plant — typically the PCBU. This includes designers, manufacturers, importers, suppliers, and the business using the plant. All have duties under the WHS Act and Regulations.

How often should plant and equipment be inspected?

Inspection frequency depends on the plant type, manufacturer's instructions, operating environment, and any legislative requirements for that plant class. High-risk plant such as cranes and pressure vessels often have mandatory inspection intervals set by regulation. At a minimum, a documented pre-start check should be completed before each shift.

Keep your plant records organised

A thorough plant and equipment safety program relies on accurate, up-to-date records — registration certificates, maintenance logs, pre-start check records, and operator competency files. Blue Safe Online provides the forms, registers, and systems to keep all of this in one place, ready for inspection.

This checklist is general guidance only and does not constitute legal advice. Requirements may vary by jurisdiction, industry, and the specific plant involved. Always verify obligations with your state WHS regulator and seek professional advice where needed.