Inspection, Testing and Servicing
Purpose
RPD plans, conducts and records inspection, testing and servicing across the things that have to stay safe over time — work sites, work methods, plant and equipment, incoming products and worker health surveillance.
Inspections, pre-starts, plant checks, service records and SDS are managed in Breadcrumb. PIMS is used for scheduled audit inspections, findings, corrective actions, trends and management review evidence.
Procedure
| Field | Requirement |
|---|---|
| Applies when | All RPD projects, from set-up through to demobilisation, and for plant, equipment and materials brought to site. |
| Owner | Project Manager sets the inspection, testing and servicing schedule. Site Supervisor runs day-to-day inspections and pre-starts. |
| Before work starts | Prepare a risk-based inspection, testing and servicing schedule covering the site, work methods, plant, electrical, height controls, hazardous substances and health surveillance triggers. |
| Minimum controls | Inspect against a known standard, by a competent person, using current equipment, with the result and test status recorded. |
| Hold point | Do not use plant, equipment, scaffold, EWPs, electrical leads, fall protection systems or high-risk controls until inspection or test status is confirmed and recorded. |
| Breadcrumb function | Inspection schedules, site inspections, pre-starts, plant inductions, plant service registers, SDS, hazard reports and incident reports. |
| Stop / escalate | Stop work where an item fails inspection, where test status cannot be verified or where exposure monitoring or health surveillance shows a control failure. Escalate repeat failures, systemic gaps or audit findings into PIMS. |
Inspection, Testing and Servicing Scope
| Area | What RPD inspects, tests or services |
|---|---|
| Incoming products | Materials, plant, equipment, hire items and chemicals checked against order, condition, SDS, test tag and any registration or certification required. |
| Work site environment | Access, exits, housekeeping, exclusion zones, public/resident interface, lighting, weather conditions and site amenities. |
| Work methods | SWMS controls in use, permits in place, supervision level, and changes to method or sequence. |
| Hazard and risk controls | Fall protection, edge protection, scaffold, EWPs, exclusion zones, dust and silica controls, lead paint controls, asbestos unexpected find controls, hot work and confined space controls. |
| Site rules and behaviour | Adherence to site rules, PPE/RPE use, SWMS sign-on and stop-work behaviour. |
| Electrical safety | Test and tag of leads, tools and RCDs, board condition, lead management, generator and temporary power arrangements. |
| Plant and equipment | EWPs, scaffolds, harness systems, anchor points, lifting gear, powered tools, pressure equipment, dust extraction and pumps inspected, tested and serviced per manufacturer, standards and licence requirements. |
| Fire and first aid equipment | Site extinguishers, fire blankets and first aid kits checked for currency, condition and accessibility. |
| Hazardous substances | Storage, labelling, segregation, spill controls, decanted container labelling and SDS currency. |
| Health surveillance triggers | Silica, lead, isocyanates, solvents, noise, vibration and other exposures identified in SWMS, monitoring or supplier information. |
Inspection and Test Plan Requirements
Each inspection and test plan, whether on the schedule or built into a SWMS, must make clear:
- The standard, code of practice, manufacturer instruction or legislative requirement the inspection or test is checked against
- What is being inspected, tested or serviced and how often
- Who is responsible and what competency or licence they need
- How the test status of plant, equipment and materials is identified, including tags, stickers, registers or quarantine
- The accuracy and calibration requirements for any testing equipment used
- How the result is recorded and where it is stored
- When a fail result triggers stop-work, quarantine, repair, retest or escalation.
Detailed Inspection and Test Register
This register sets the minimum methodology, frequency, inspector competency and reference standard for the key plant, equipment and systems used on RPD remedial, painting, facade, waterproofing and breakout work. OEM (manufacturer) instructions take priority where they are more frequent or more stringent than the legislated minimum.
| Item | Methodology | OEM / Legislated inspection or test period | Inspector | Standard / Legislation / CoP |
|---|---|---|---|---|
| Rope access equipment (harness, ropes, carabiners, descenders, ascenders, lanyards) | User pre-use visual and functional check before each work day. Detailed inspection by a competent height safety / rope access inspector with tag and register. Quarantine on any fall, shock load, chemical contact or doubt. | Pre-use each work day; 6-monthly detailed inspection; manufacturer service life (commonly 10 years for textiles). | User for pre-use. Competent rope access / height safety inspector for detailed inspection (IRATA / SPRAT or AS/NZS 1891.4 competent person). | AS/NZS 4488 Industrial rope access systems; AS/NZS 1891 series; IRATA ICOP; manufacturer instructions. |
| EWPs (boom lift, scissor lift, vertical lift) | Operator pre-start. Routine, periodic and major inspections per AS 2550.10. Annual inspection and 10-year major inspection by manufacturer-accredited inspector. | Pre-start each work day; 3-monthly routine; 12-monthly annual; 10-year major inspection. | Operator with HRW WP licence where boom > 11 m and VOC. Competent person for periodic. Manufacturer-accredited inspector for 10-year major. | AS 2550.10; AS 1418.10; WHS Regulation 2017 (NSW) Chapter 5 Plant; manufacturer service manual. |
| Scaffold (modular, tube and coupler, mobile) | Handover inspection on completion. Inspection before use, after alteration, after impact, after adverse weather and at set intervals. Scaftag or equivalent applied. | At handover; after any alteration, impact or adverse weather; and at least every 30 days. | Scaffolder with appropriate HRW licence (Basic, Intermediate or Advanced) for erect, alter and dismantle. Competent person for periodic inspection. | WHS Regulation 2017 (NSW) clause 225; AS/NZS 1576 series; AS/NZS 4576; SafeWork NSW Code of Practice — Scaffolds and Scaffolding Work. |
| Swing stage scaffold (suspended scaffold) | Pre-use daily check by operator. Periodic inspection by competent scaffolder. Anchor and suspension rope test on install and at recertification. | Pre-use each work day; monthly competent person inspection; 12-monthly recertification of system, ropes and winch. | Advanced scaffolder for erect, alter and dismantle. Operator pre-use. Manufacturer-accredited agent for winch and rope recertification. | AS/NZS 1576.4 Suspended scaffolds; WHS Regulation 2017 (NSW); SafeWork NSW Code of Practice — Scaffolds and Scaffolding Work; manufacturer instructions. |
| Harness systems (full body harness, lanyards, energy absorbers, SRLs, rescue kits) | User pre-use visual check. Detailed inspection by competent height safety inspector with tag and register. Quarantine on any fall arrest event or shock load. | Pre-use each work day; 6-monthly detailed inspection; manufacturer service life (commonly 10 years). | User for pre-use. AS/NZS 1891.4 height safety competent inspector for detailed inspection. | AS/NZS 1891.1–.4 Industrial fall-arrest systems and devices; manufacturer instructions. |
| Anchor points (single point and horizontal lifeline systems) | Installed and certified by competent installer with proof load test on install. Annual recertification. Re-inspection after any fall or impact. | At install with certification; 12-monthly recertification; after any fall arrest event. | AS/NZS 1891.4 height safety installer / inspector. Structural engineer where required by design. | AS/NZS 1891.2 and 1891.4; manufacturer instructions; building structural certification where required. |
| Lifting gear (chain slings, flat and round synthetic slings, shackles, hooks, eye bolts) | Pre-use visual by user. Periodic inspection by competent person with tag and register. Colour-coded tagging system. Quarantine on any damage, overload or wear beyond tolerance. | Pre-use each lift; 3-monthly competent person inspection for chain slings; 6 to 12-monthly for synthetic slings and accessories per manufacturer. | Competent rigger or lifting gear inspector. Dogman / rigger with HRW licence for the lift. | AS 3775 Chain slings; AS 1353 Flat synthetic-webbing slings; AS 4497 Round synthetic slings; AS 3776 Lifting hooks; AS 4991 Lifting devices; WHS Regulation 2017 (NSW) Chapter 5 Plant. |
| Electrical tools and equipment (portable tools, leads, extension cords, power tools) | Visual pre-use check. Test and tag with current tag. Quarantine on damage, missing tag or test failure. | Pre-use each work day; test and tag every 3 months on construction and demolition sites. | Competent person for test and tag (Class 2A or equivalent). Licensed electrician for any repair. | AS/NZS 3012 Electrical installations — construction and demolition sites; AS/NZS 3760 In-service safety inspection and testing. |
| RCDs (portable and fixed) | Push-button trip test. Trip-time and trip-current test using calibrated tester. Quarantine on any failure. | Portable RCDs: push-button daily and trip-time test every 3 months. Fixed RCDs on temporary supply: push-button monthly, trip-time 12-monthly. | Competent person for push-button. Licensed electrician for trip-time test. | AS/NZS 3012; AS/NZS 3760; AS/NZS 3000 Wiring Rules. |
| Temporary meter boards and site distribution boards | Commissioning inspection and test on install. Periodic inspection of board, RCDs, leads, earthing and weatherproofing. | Inspected on install; monthly visual; 6-monthly test of board, RCDs and earthing. | Licensed electrician for install, commissioning and periodic test. | AS/NZS 3012; AS/NZS 3000; local network service rules; WHS Regulation 2017 (NSW). |
| Excavators and other earthmoving plant | Operator pre-start each work day. Scheduled service per OEM. Periodic inspection of attachments, hoses, ROPS/FOPS, quick hitch and safety systems. | Pre-start each work day; OEM service intervals (e.g. 250 / 500 / 1000 hours); 12-monthly inspection; major inspection per OEM. | Operator with VOC. Qualified plant mechanic for service. Competent person for periodic inspection. | WHS Regulation 2017 (NSW) Chapter 5 Plant; AS 2550 series; manufacturer service schedule. |
| Concrete pump (boom and line pump) | Operator pre-start. Scheduled service per OEM. Periodic inspection of boom, outriggers, pipework, clamps, hoses and safety devices. Pipework wall-thickness testing and boom non-destructive testing per OEM and industry guidance. | Pre-start each work day; OEM service intervals; 12-monthly inspection; pipework wall-thickness testing per OEM (typically every 3 to 6 months under use); major inspection per AS 2550.15 (commonly 10 years). | HRW PB-licensed operator for concrete placing boom. Competent person for periodic inspection. Manufacturer-accredited inspector for major inspection and boom NDT. CPAA-aligned inspector where applicable. | AS 1418.15 and AS 2550.15 Cranes — concrete placing equipment; WHS Regulation 2017 (NSW) Chapter 5 Plant; CPAA guidelines; manufacturer instructions. |
| Crane (mobile, tower, vehicle-loading) | Operator pre-start. Routine, periodic and major inspections per AS 2550 series. Registered plant design and registered item of plant evidence held where required. Load testing on install or repair. | Pre-start each work day; 3-monthly routine inspection; 12-monthly annual inspection; major inspection per AS 2550 part (commonly 10 years or set hours). | HRW-licensed crane operator and dogman / rigger for the lift. Competent person for periodic inspection. Manufacturer-accredited inspector for major inspection. | AS 1418 and AS 2550 series; WHS Regulation 2017 (NSW) Chapter 5 Plant and Schedule 5 registered plant; SafeWork NSW Code of Practice — Cranes; manufacturer instructions. |
| Scaffold winch and powered suspended platform hoist | Pre-use functional test by operator. Periodic inspection by competent scaffolder. Manufacturer-accredited service and recertification. Rope replacement per manufacturer. | Pre-use each work day; monthly inspection; 12-monthly recertification; OEM service intervals. | Operator for pre-use. Advanced scaffolder for periodic inspection. Manufacturer-accredited service agent for recertification. | AS/NZS 1576.4 Suspended scaffolds; AS 1418.13 where applicable; WHS Regulation 2017 (NSW); manufacturer instructions. |
Health Surveillance and Exposure Monitoring
RPD identifies health surveillance and exposure monitoring triggers through the SWMS, project risk assessment and SDS review. Typical triggers on RPD work are silica, lead, asbestos unexpected finds, solvents and isocyanates, noise and hand-arm vibration. Audiometric testing applies to workers regularly required to wear hearing protection — baseline within 3 months of starting trigger work and at least every 2 years after that.
Health monitoring is carried out or supervised by a registered medical practitioner with relevant experience. Exposure monitoring is planned and overseen by a qualified occupational hygienist with NATA-accredited laboratory analysis. Records are managed through HR and the project file, with WHS implications and control changes captured in PIMS.
Health monitoring reports are confidential, kept at least 30 years (40 years for asbestos), and released only with the worker's written consent or where disclosure is required by law.
Pre-employment medical assessment, drug and alcohol testing and general fitness for work arrangements are managed under the RPD HR Manual and are not duplicated here.
Detailed Health Surveillance and Exposure Monitoring Register
This register sets the minimum methodology, frequency, provider competency and reference standard for the hazards and exposures most likely to arise on RPD remedial, painting, facade, waterproofing and breakout work. Where SDS, exposure assessment or a registered medical practitioner sets a more frequent or more stringent requirement, that requirement takes priority.
| Hazard / Exposure | Methodology | Frequency / Period | Conducted by | Standard / Legislation / CoP |
|---|---|---|---|---|
| Crystalline silica (concrete breakout, grinding, cutting, render, facade, masonry) | Baseline health monitoring with respiratory emphasis, occupational and exposure history, spirometry and review by registered medical practitioner. Air monitoring of respirable crystalline silica where exposure may exceed the workplace exposure standard or control effectiveness is uncertain. | Baseline before exposure starts; ongoing frequency set by the registered medical practitioner; air monitoring on exposure change, new task or control failure. | Registered medical practitioner with relevant experience for health monitoring. Qualified occupational hygienist with NATA-accredited laboratory for air monitoring. | WHS Regulation 2017 (NSW) Part 7.1 and Schedule 14; crystalline silica substance provisions effective 1 September 2024; SafeWork NSW Crystalline Silica guidance and Code of Practice; AS 2985 Workplace atmospheres — respirable dust. |
| Lead (lead paint disturbance, removal, sanding, burning, blasting) | Biological monitoring by blood lead level. Baseline before lead-risk work, then frequency by result and worker category. Health monitoring by registered medical practitioner. | Baseline before exposure. For males and females not of reproductive capacity: 6-monthly if last result < 10 µg/dL; 3-monthly if 10 to < 20 µg/dL; 6-weekly if ≥ 20 µg/dL. For females of reproductive capacity: 3-monthly if < 5 µg/dL; 6-weekly if 5 to < 10 µg/dL. | Registered medical practitioner with relevant experience. | WHS Regulation 2017 (NSW) Part 7.2 Lead; Schedule 14; SafeWork NSW Lead Code of Practice. |
| Asbestos (licensed asbestos removal work and asbestos-related work where exposure risk) | Health monitoring including medical and exposure history, respiratory assessment and review by registered medical practitioner. Air monitoring during licensed removal per asbestos requirements. | Before the worker starts licensed removal or asbestos-related work; ongoing frequency set by the registered medical practitioner; air monitoring per asbestos removal control plan. | Registered medical practitioner with relevant experience for health monitoring. Licensed asbestos assessor or qualified occupational hygienist for air monitoring; NATA-accredited laboratory for analysis. | WHS Regulation 2017 (NSW) Part 8.5 and Chapter 8; SafeWork NSW Code of Practice — How to Manage and Control Asbestos and How to Safely Remove Asbestos; asbestos health monitoring records to be kept at least 40 years. |
| Isocyanates (2-pack paints, polyurethane coatings, some sealants) | Pre-placement and periodic medical assessment with respiratory questionnaire, spirometry and skin assessment. Air monitoring where exposure may exceed the workplace exposure standard. | Baseline before exposure; ongoing frequency by registered medical practitioner; air monitoring on task or control change. | Registered medical practitioner with relevant experience. Qualified occupational hygienist with NATA-accredited laboratory for air monitoring. | WHS Regulation 2017 (NSW) Part 7.1 and Schedule 14; Workplace Exposure Standards for Airborne Contaminants (Safe Work Australia); SDS; manufacturer instructions. |
| Organic solvents and VOCs (paints, thinners, strippers, sealants, two-pack systems) | Exposure assessment from SDS and task review. Air monitoring where exposure uncertain or control effectiveness is in doubt. Medical assessment where the chemical or task triggers Schedule 14 or the SDS calls for it. | Per risk assessment; before significant exposure; ongoing per registered medical practitioner where triggered. | Qualified occupational hygienist with NATA-accredited laboratory for air monitoring. Registered medical practitioner for health monitoring. | WHS Regulation 2017 (NSW) Part 7.1 and Schedule 14; Workplace Exposure Standards for Airborne Contaminants; SDS. |
| Noise (concrete breakout, grinding, cutting, needle gunning, spray application, powered tool use, dust extraction plant) | Audiometric testing by pure tone air conduction. Noise exposure assessment of tasks and plant. Engineering and PPE controls reviewed where exposure exceeds the standard. | Baseline within 3 months of the worker starting trigger work; follow-up audiometric testing at least every 2 years while exposure continues. | Competent audiometrist or occupational audiologist for testing. Competent person or occupational hygienist for noise exposure assessment. | WHS Regulation 2017 (NSW) Part 4.1 Noise; AS/NZS 1269 series Occupational noise management; SafeWork NSW Code of Practice — Managing Noise and Preventing Hearing Loss at Work. |
| Hand-arm vibration (rotary hammers, breakers, grinders, needle guns, sanders) | Exposure assessment from tool vibration magnitude and trigger time. Health surveillance by medical and vascular / neurological assessment where exposure exceeds the action value. | Baseline before exposure where action value is likely exceeded; ongoing per registered medical practitioner (typically annual). | Competent person for exposure assessment. Registered medical practitioner with relevant experience for health surveillance. | ISO 5349 Mechanical vibration — hand-transmitted vibration; AS 2670; Safe Work Australia Hand-Arm Vibration guidance; manufacturer vibration data. |
| Airborne contaminants — general (dusts, fumes, gases, mists) | Air monitoring against the relevant method (e.g. AS 2985 for respirable dust). Sampling planned and overseen by a qualified occupational hygienist; analysis by a NATA-accredited laboratory; results interpreted and recommendations made by the occupational hygienist. | Where required by legislation; where uncertain whether the exposure standard is exceeded; to verify control effectiveness; on task or control change. | Qualified occupational hygienist with NATA-accredited laboratory. | Workplace Exposure Standards for Airborne Contaminants (Safe Work Australia); WHS Regulation 2017 (NSW) Part 7.1; AS 2985 and related sampling standards; SDS. |
| Hazardous chemicals — Schedule 14 trigger | Identify Schedule 14 chemicals from the SDS and chemical register during risk assessment. Where a significant health risk exists, arrange health monitoring per Schedule 14 requirements and the registered medical practitioner. | Before the worker starts the work that triggers health monitoring; ongoing per registered medical practitioner. | Registered medical practitioner with relevant experience. | WHS Regulation 2017 (NSW) Part 7.1 Division 6 and Schedule 14; SafeWork NSW guidance for the relevant chemical. |
Records and Evidence
| Record | System / location | Evidence required |
|---|---|---|
| Inspection, testing and servicing schedule | Project file / Breadcrumb | Risk-based schedule covering site, plant, electrical, height controls, fire and first aid equipment, hazardous substances and health surveillance triggers, prepared before work starts. |
| Site inspection | Breadcrumb | Inspection date, inspector, items checked, defects, actions and close-out. |
| Pre-start / plant inspection | Breadcrumb | Daily or work-day pre-start, operator, plant ID, defects and out-of-service action where required. |
| Plant and equipment register | Breadcrumb | Plant item, registration or certification, service intervals, last service, next due and current test status. |
| Electrical test and tag | Project file / appendix register | Item ID, tester, date, retest date and tag status. |
| Scaffold, EWP, harness and anchor inspection | Breadcrumb | Inspection by competent person, handover or recurring check, defects and re-inspection. |
| Lifting gear | Project file / appendix register | Item ID, rated capacity, inspection date, condition and next due. |
| Fire and first aid equipment | Project file / appendix register | Item, location, currency, condition and last check. |
| SDS and hazardous substance check | Breadcrumb | Current SDS, register entry, labelling, storage and spill controls. |
| Calibration of testing equipment | Project file / supplier record | Calibration certificate, due date and use limits. |
| Health surveillance / exposure monitoring | HR file | Worker health surveillance record, exposure monitoring result, control change and follow-up. |
| Audit inspection and corrective action | PIMS | Scheduled audit inspection, finding, root cause, corrective action, close-out and effectiveness check. |
Quick Guide
| Step | What RPD checks |
|---|---|
| 1. Plan the schedule | Build a risk-based inspection, testing and servicing schedule before work starts and update it as the project changes. |
| 2. Check incoming products | Inspect materials, plant, equipment and chemicals on arrival against order, condition, test tag, registration and SDS. |
| 3. Run pre-starts | Use Breadcrumb pre-starts for plant, EWPs, scaffolds, leads, tools and fall protection equipment each work day or use. |
| 4. Confirm test status | Do not use plant, equipment or electrical items where the test or service status cannot be verified. |
| 5. Inspect the site | Walk the site against the schedule, site rules and SWMS controls, and record findings in Breadcrumb. |
| 6. Watch exposure triggers | Identify silica, lead, solvent, noise and other exposures and apply the required monitoring or health surveillance. |
| 7. Quarantine and act | Tag out, quarantine or remove failed items, fix the cause and retest before return to service. |
| 8. Escalate the pattern | Record site-level actions in Breadcrumb. Escalate repeat failures, systemic gaps or audit findings into PIMS. |
Scope Note
This section covers WHS-side inspection, testing and servicing only — the checks that keep work sites, plant, equipment and worker health safe. Construction quality inspection and test plans — the workmanship hold and witness points for concrete repair, waterproofing, facade, painting, tiling and reinstatement work — are managed separately under RPD's construction quality framework.