Plant and machinery can introduce a range of risks to your workers and operations. A plant risk assessment helps you identify those hazards by understanding the level of risk involved and putting controls in place to reduce them.
Our plant risk assessments provide a structured review of your equipment and operating environment, along with findings and recommendations documented in a clear report.
Assessments are designed to support your WHS obligations and alignment with relevant machinery safety standards, including the AS 4024 series.
Request a consultation with our Adelaide team today.
Who Needs a Plant Risk Assessment?
Any business that designs, imports, supplies, installs, or operates plants has a legal duty to manage workplace risks.
Under WHS laws, duty holders include PCBUs (persons conducting a business or undertaking), designers, manufacturers, importers, suppliers, installers, and those with managerial or supervisory control over plant operations. This includes:
- Manufacturing and Processing
- Brewing and Food & Beverage
- Mining and Heavy Industry
- Defence and Government Industrial Facilities
- Chemical and Pharmaceutical Manufacturing
- Construction and Civil Infrastructure
- Recycling and Waste Management
- Transport and Logistics
- Warehousing and Distribution
If you are responsible for plant equipment operation in any of these settings, a formal risk assessment helps you identify hazards and demonstrate compliance with your workplace health and safety duties.
What Our Plant Risk Assessment Covers
Our assessments cover the following:
Hazard Identification
We look at your plant, how it’s used, and the environment it operates in to identify potential sources of harm, including mechanical, electrical, hydraulic, pneumatic, ergonomic and chemical hazards.
Risk Rating
We assess the likelihood and consequence of each hazard, helping you understand which risks need attention and how they change once controls are in place.
Control Recommendations
We recommend ways to reduce risk, following the hierarchy of control. That means looking at elimination, substitution, engineering controls and isolation before relying on administrative measures or PPE.
Legislation and Standards Review
We check relevant WHS legislation, the AS 4024 series, and other plant-specific requirements.
Written Report
You’ll receive a clear report outlining the hazards identified, risk ratings, recommended controls, compliance gaps, along with the next steps for your team.
If the assessment identifies areas that need attention, our broader engineering consulting services can also help with machine safety upgrades. Our team also reviews relevant WHS legislation and applicable standards, including the AS4024 series, where relevant.
How the Assessment Works
We follow a practical and transparent process tailored to your operation.
1. Site review and scope
We walk through your plant with your team to understand your equipment and where risks may arise.
2. Hazard identification
We identify potential hazards across machinery, tasks, and operating environments.
3. Risk assessment
We evaluate the likelihood and potential risks of each hazard.
4. Control recommendations
We recommend practical measures to reduce risk, with clear responsibilities and implementation timeframes.
5. Written report
You receive a structured report outlining the findings, recommended actions, and next steps, giving your team a practical reference for ongoing risk management.
Why Choose Ingenia?
Over the years, we’ve built our reputation in Adelaide on the principles of practicality, reliability, and efficiency as leading consulting engineers. We understand the operational pressures manufacturers face and work alongside your team to deliver practical safety outcomes that minimise disruption and support compliance.
Multidisciplinary Expertise
Our team supports projects from concept through implementation, ensuring safety is considered throughout the project lifecycle.
15+ Years of Experience
Founded in 2009, our engineering consulting services have supported brownfield and greenfield projects from concept through to commissioning.
Machine Safety Expertise
From machine safety consulting to Safety in Design and HAZOP facilitation, we help you meet compliance with minimal disruption
Learn more about Ingenia or meet our people.
Related Engineering and Risk Services
If your assessment identifies broader operational or machinery risks, our engineering team can help you take the next step. Explore our related services:
Book a Plant Risk Assessment
Whether you’re reviewing existing equipment, preparing for an audit, or looking to better manage operational risks, Ingenia can help.
FAQs
What is included in the plant risk assessment report?
The report will typically include:
- Hazard register
- Risk ratings
- Control measures
- Compliance references
- Action plan
How often should a plant be reassessed?
At least every 1–2 years, or immediately after an incident, a change to the plant process, new legislation, or if controls are found to be ineffective.
Do you only work in Adelaide and South Australia?
No. While our team is based in Adelaide, we support clients across Australia with plant risk assessments and broader engineering consulting services.
