Folder, Press Brake P ERA

PRESS BRAKE
Heavy Duty - Electro Hydraulic
SCOPE
This document is to be completed for staff and student use of machinery,
plant & equipment as a part of a school curriculum activity or program.
Refer to the ITD Guidelines for further staff advice on the risk
management process for practical ITD curriculum activities in schools.
Plant / Equipment Description:
Teachers / Leaders:
Room Locations:
Assessment Date:
Review Date:
N.B. This assessment can remain active for up to 5 years. However, an annual monitoring & review process
should be undertaken and recorded – refer to the last page of this document.
Below are the details of the manufacturing or production processes attributed to this item of equipment categorised
by their assessed inherent risk levels (refer to the Equipment / Process Risk Matrix). The actions required for
approval for each level of inherent risk are mandatory.
Inherent Risk Level
Details of Process




Medium
High
Extreme
When this heavy duty press brake is used
correctly and carefully for the purposes for
which it was designed. Never bend or fold
beyond the capacity of the machine.

When the bending or folding operation is
performed by one person only, with observer.

When bending or folding one piece of sheet
metal of flat bar at any one time.

When the “V” forming blocks and the knife
blades are correctly aligned and checked.

When the bending or folding operation requires
that the head rams be adjusted by an ITD
teacher to suit the material thickness.

When circumstances require that both hands
must be positioned close to the pinch area of
the clamping bar, material and bending blade.

When it is recommended that junior students do
not have access to this machinery.

When a heavy duty press brake operation is
included in a senior ITD curriculum where
students are always under the appropriate
supervision of a qualified ITD teacher.

Action Required / Approval

Document controls in planning
documents and/or complete this
Plant Risk Assessment.
 Consider obtaining parental
permission.
 A Plant Risk Assessment is
required to be completed.
 Principal or Classified Officer (i.e.
DP, HOD, HOC, HOSES) approval
prior to conducting this activity is
required.
 Obtaining parental permission is
recommended.

Consider alternatives to using the
plant / equipment.
 A Plant Risk Assessment is
required to be completed.

Principal approval prior to
N.B. This machine should not operate if the
conducting this activity is required.
infra-red beam or electronic sensors are
breached in any way either by material or by the  Parental permission must be
obtained for student participation.
operator.
DETE - Organisational Health Unit
Page 1 of 7
Issued: November, 2013. V3
Uncontrolled when printed
Minimum Standards
Minimum Qualifications and Experience
Listed below are the general “Minimum” recommendations for the management of this Plant / Equipment.

Indicate the minimum management controls.
Registered teachers with experience, ability and competency in the safe use of this plant / equipment
(indicate one or more of the following):
Specific knowledge of the safe and correct use of this plant / equipment;
Experience (i.e. previous involvement and familiarity) in the safe use of this plant / equipment;
Demonstrated expertise, ability and competency with this plant / equipment;
Documented qualifications relating to the use of this plant / equipment ( e.g. in a staff profile )
OR
An adult staff member or leader, other than a registered teacher, with :
Expertise in the safe and correct use of this plant / equipment;
Documented qualifications that demonstrate experience, ability and competency in the safe use
of this plant / equipment.
Will any ITD staff require initial and/or ongoing training for the safe use of this plant / equipment ?
If yes, give details:
Will students be operating this plant / equipment ?
If yes, state how student use of this plant / equipment will be managed ( e.g. Workshop Safety Induction )
Give details:
Further information if required:
Minimum Control Requirements
Supporting documentation available in the school on this plant / equipment includes:
Operators Manual
Safe Operating Procedures – (SOP)
Equipment Maintenance Records – (EMR)
A process for recording student safety induction
( link to example )
A process for recording staff training & experience – e.g. ITD Staff Profile
( link to example )
All guards are in place & in good working order for this plant / equipment
Safe Working Zones are defined for this plant / equipment (e.g. yellow lines and / or appropriate signage)
Suitable personal protective equipment (PPE) is available to be used by all operators
This plant / equipment complies with relevant safety standards
Further information if required:
DETE - Organisational Health Unit
Page 2 of 7
Issued: November, 2013. V3
Uncontrolled when printed
Hazards and Control Measures
Listed below are indicative hazards/risks and suggested control measures. They are by no means exhaustive lists.
Add details of any other hazards/risks or additional controls you intend to implement.

Indicate the Control Measures adopted. Detail their implementation and any additional controls required.
Hazards/Risks
Exposure to Rotating
or Moving Parts:
 Entanglement &
Entrapment
Could hair, clothing, ties,
jewellery or other materials
become entangled with
moving parts of plant or
materials in motion?
 Striking
Could anyone be struck by
moving objects such as the
workpiece being ejected, or by
the unexpected or
uncontrolled movement of the
plant or workpiece?
 Crushing & Pinching
Could anyone be crushed or
pinched due to falling,
uncontrolled or unexpected
movement of plant or its load
tipping or rolling over, or
contact with moving parts
during testing, inspection or
maintenance?
 Shearing
Can body parts be cut off
between two parts of the
plant, or between a part of the
plant & the workpiece or
structure?
Hierarchy of Recommended
Control Measures
Yes
No
Details of how this will
be implemented
( and any additional controls )
1. Where possible, potentially hazardous
plant, machinery and processes, including
the heavy duty electro-hydraulic press
brake, are substituted or replaced with less
hazardous alternatives.
2. All necessary press brake guards,
enclosures & safety devices are in place
protecting workers from all moving parts.
3. Micro switches are fitted that cut off power
when covers, enclosures or guards are
opened.
4. “Lock Out” or warning “Danger” tags are
affixed to the press brake when under
repair or maintenance preventing workers
from using the equipment.
5. Staff & student training is provided to
minimise exposure to these hazards.
6. Safe operating procedures (SOP’s) for the
press brakes are available & clearly
displayed.
7. “Safe Working Zones” around the press
brake are clearly defined by yellow safety
lines – (or similar).
8. Emphasis is placed on the requirement for
plant operators to remove all jewellery, tuck
in loose clothing & tie back long hair.
9. All appropriate and approved personal
protective equipment (PPE) is used where
required.
 Cutting, Stabbing
& Puncturing
Can anyone be cut, stabbed
or punctured by coming into
contact with moving plant or
parts, or objects such as
ejected workpiece or waste?
Slips, Trips, Falls &
Abrasions:
Can anyone using the plant or
in the vicinity of the plant, slip,
trip or fall due to the working
environment or other factors?
Poor housekeeping, dust on
floors, slippery or uneven work
surfaces, power cables across
work areas causing injuries &
abrasions?
1. Slip resistant flooring is encouraged.
Regular checks are made for unsafe wear
& damage. Inspections are made for any
power leads or hoses, etc.
2. Procedures are in place for the disposal of
all waste materials around the powered
press brake.
3. Staff training is provided to minimise
exposure to these hazards.
DETE - Organisational Health Unit
Page 3 of 7
Issued: November, 2013. V3
Uncontrolled when printed
Hazards/Risks
Environmental:
 Noise
Is it likely that the normal
operation of this plant will
produce excessive noise
levels?
Hierarchy of Recommended
Control Measures
No
Details of how this will
be implemented
( and any additional controls )
1. The powered press brake is regularly
inspected & maintained to reduce
inaccuracies and to help minimise the risk
of exposures to these hazards.
2. All powered press brake maintenance is
documented in a register - (EMR’s).
 Dust, Fumes &
Vapours
3. Exposure to noisy ITD workshop
environments is monitored & evaluated
regularly for all workers.
Is it likely there will be airborne
dust particles, toxic fumes or
volatile vapours produced &
therefore be present in the
workspace?
4. Engineering controls (or physical changes)
such as mandatory machinery guarding or
any protective safety screens & enclosures
are in place in all workspaces & all in good
working condition.
 Lighting
5. Staff & student training is provided to
minimise exposure to these hazards.
Is there insufficient lighting to
operate this plant in a safe
manner? Is there a possible
strobe lighting effect caused
by faulty fluorescent tubes in
the workspace?
Yes
6. All waste extraction systems are connected
and operational, fully maintained and
cleaned as required.
7. Good lighting is provided to all workspaces
and this is maintained on a regular basis.
Fluorescent tubes are checked & replaced
as required.
8. All appropriate and approved personal
protective equipment (PPE) is used where
required.
Electrical:
Can the operator be injured by
electrical shock due to
working near or contacting
with damaged or poorly
maintained live electrical
conductors such as power
outlets, extension leads,
safety switches, starters &
isolators or casual water on
the floor near plant &
machinery?
1. The powered press brake has a wall or
machine mounted isolating switch that
disconnects all motive power.
2. The powered press brake is fitted with a
Direct on Line (DOL) Start/Stop switch (Red & Green buttons).
3. An Emergency stop button is mounted
prominently where necessary.
4. “Lock Out” or warning “Danger” tags are
affixed to the powered press brake when
under repair or maintenance preventing
workers from using the equipment.
5. Visually checks are made of all electrical
switches, plugs & power leads, etc.
6. Electrical safety inspections, testing &
tagging, etc. are completed regularly as per
guidelines for the powered press brake.
7. Electrical maintenance on all plant &
equipment, including the powered press
brake, is documented in EMR’s.
DETE - Organisational Health Unit
Page 4 of 7
Issued: November, 2013. V3
Uncontrolled when printed
Hazards/Risks
Exposure:
 Friction
Is the plant likely to generate
heat by friction? Could the
plant operator accidentally
come into contact with moving
materials or machinery
components resulting in
friction burns to the skin,
particularly hands?
 Hazardous
Substances
Is it likely that the plant
operator or others nearby in
the workspace could be
exposed to hazardous or toxic
chemicals such as oils,
hydraulic fluids, greases,
coolants, volatile vapours,
fumes or airborne toxic wood
dust particulates?
Ergonomics &
Manual Handling:
Can the plant be safely
operated, in a suitable
location, providing clear &
unobstructed access?
Poorly designed work stations
often necessitate teachers &
students performing manual
tasks involving heavy lifting &
lowering, pushing, pulling or
carrying, etc. Such tasks then
contribute to a range of
musculoskeletal sprains &
strains for workers.
Hierarchy of Recommended
Control Measures
Yes
No
Details of how this will
be implemented
( and any additional controls )
1. The powered press brake is regularly
inspected & maintained to help minimise
the risk of exposures to these hazards.
2. Press brake maintenance is documented in
a register - (EMR’s).
3. Any hazardous waste material or toxic
dusts & vapours resulting from this
manufacturing process are monitored and
managed.
4. Staff & student training is provided to
minimise exposure to these hazards.
5. “Safe Working Zones” around the press
brake are clearly defined by yellow safety
lines – (or similar).
6. All appropriate and approved personal
protective equipment (PPE) is used where
required.
1. The powered press brake & the adjacent
work benches are planned & adjusted to a
comfortable work height thus minimizing
any unsafe or excessively strenuous
manual tasks.
2. Sufficient workspace is provided in all
practical classrooms to help ensure
unobstructed, safe operation.
3. Safe Working Zones are clearly defined
around all fixed plant including the heavy
hydraulic press brake. Floors are free of
excessive wood dust, waste materials &
other extraneous objects.
4. Staff training is provided with regard to
manual handling techniques & procedures
to minimise exposure to these hazards.
DETE - Organisational Health Unit
Page 5 of 7
Issued: November, 2013. V3
Uncontrolled when printed
Additional Control Measures
Other Hazards/Risks
These would relate to the specific student needs, locations and conditions in which you are
conducting your activity.
Approval
Submitted by:
Date:
Approved as submitted.
Approved with the following condition(s):
Not Approved for the following reason(s):
By:
Designation:
Signed:
Date:
ITD staff members involved in the use of this risk assessment & the associated plant & equipment:

Signature: ………………………………..
Date:
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Signature: ………………………………..
Date:
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Signature: ………………………………..
Date:
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Date:
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Date:
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Date:
DETE - Organisational Health Unit
Page 6 of 7
Issued: November, 2013. V3
Uncontrolled when printed
Monitoring and Review
This Plant & Equipment Risk Assessment is to be monitored and reviewed annually for a further four (4) years
Review 1:
Yes
No
 Are allocated risk levels and “Actions Required” unchanged over the past 12 months ?
 Are Minimum Standards and Recommended Control Measures unchanged over 12 months ?
 ITD staffing details at this school have remained unchanged over the past 12 months ?
If the responses are “NO” for any question, record current details here, and list all staff changes (with signatures)
Reviewed by:
Designation:
Signed:
Review Date :
Review 2:
Yes
No
 Are allocated risk levels and “Actions Required” unchanged over the past 12 months ?
 Are Minimum Standards and Recommended Control Measures unchanged over 12 months ?
 ITD staffing details at this school have remained unchanged over the past 12 months ?
If the responses are “NO” for any question, record current details here, and list all staff changes (with signatures)
Reviewed by:
Designation:
Signed:
Review Date :
Review 3:
Yes
No
 Are allocated risk levels and “Actions Required” unchanged over the past 12 months ?
 Are Minimum Standards and Recommended Control Measures unchanged over 12 months ?
 ITD staffing details at this school have remained unchanged over the past 12 months ?
If the responses are “NO” for any question, record current details here, and list all staff changes (with signatures)
Reviewed by:
Designation:
Signed:
Review Date :
Review 4:
Yes
No
 Are allocated risk levels and “Actions Required” unchanged over the past 12 months ?
 Are Minimum Standards and Recommended Control Measures unchanged over 12 months ?
 ITD staffing details at this school have remained unchanged over the past 12 months ?
If the responses are “NO” for any question, record current details here, and list all staff changes (with signatures)
Reviewed by:
Designation:
Signed:
Review Date :
DETE - Organisational Health Unit
Page 7 of 7
Issued: June, 2013. V3
Uncontrolled when printed