Automotive Mechanical Repair SWMS
General automotive mechanical repair — vehicle hoist operation, jack and stand protocol, battery disconnection, air-con refrigerant handling, oil/fuel management and brake-dust exposure (pre-2003 vehicles may contain chrysotile asbestos).
SWMS variants reference your state’s WHS legislation. Instant download after payment.
Automotive mechanical repair workshops combine powered mobile plant, hazardous chemicals, stored mechanical energy and legacy asbestos-containing components into a single high-risk environment. Vehicle hoists are classified as powered mobile plant under WHS Regulation 2025 Part 4.5, brake friction materials in pre-2003 vehicles may contain chrysotile asbestos triggering Part 8.1 duties, and refrigerants, fuels, oils and coolants are regulated hazardous chemicals under Part 7.1. A Safe Work Method Statement is mandatory whenever the work involves powered mobile plant, work on or near energised electrical installations (battery systems and EV traction packs), or potential disturbance of asbestos — all of which routinely occur in mechanical repair. This SWMS documents the hazard identification, control selection and worker consultation required under sections 19, 38 and 47 of the model WHS Act, and provides the written method statement a PCBU must produce on request by the regulator.
Hazards identified
7 hazards covered, sorted by priority.
Catastrophic crush injury, fatality, prosecution under WHS Reg 2025 Part 4.5 and AS/NZS 2550.9 non-compliance findings
Mesothelioma, asbestosis and lung cancer with 20-40 year latency, mandatory notification to regulator
Frostbite, asphyxiation in confined bays, Ozone Protection Act breach and significant Commonwealth penalties
Second-degree burns, eye injury from molten metal, hydrogen gas explosion in poorly ventilated bays
Flash fire, full-thickness burns, workshop destruction and breach of WHS Reg 2025 Part 7.1 hazardous chemicals duties
Subcutaneous fluid injection requiring surgical debridement, potential amputation, permanent tissue necrosis if untreated
Lumbar disc injury, rotator cuff tears, chronic workers compensation claims under WHS Reg 2025 Part 4.2
Control measures
Hierarchy-of-controls order: elimination → substitution → isolation → engineering → administrative → PPE.
- 1Elimination — Remove brake servicing on pre-2003 vehicles from scope where ACM presence is confirmed; refer to licensed asbestos removalist under WHS Reg 2025 Part 8.10.
- 2Elimination — Use diagnostic scan tools to identify faults without disassembly, eliminating exposure to pressurised systems, hot components and stored mechanical energy where possible.
- 3Substitution — Replace solvent-based brake cleaners with water-based aqueous brake washers (AS/NZS 60079 compliant) to remove flammable atmosphere and respiratory hazard.
- 4Substitution — Specify low-toxicity, biodegradable degreasers in place of chlorinated solvents to reduce Part 7.1 hazardous chemicals register obligations and exposure standards risk.
- 5Engineering — Operate only AS/NZS 2550.9 compliant vehicle hoists with current six-monthly inspection records, automatic safety locks engaged and rated capacity plate visible at controls.
- 6Engineering — Install mechanical exhaust extraction at each bay (minimum 0.5 m/s capture velocity) and dedicated refrigerant recovery stations licensed under ARCtick scheme.
- 7Administrative — Conduct documented pre-start inspection of hoist arms, locks and hydraulics each shift; record vehicle weight verification against hoist SWL before lifting.
- 8Administrative — Restrict A/C refrigerant work to ARCtick-licensed technicians; isolate batteries using documented lock-out-tag-out procedure aligned to AS/NZS 4836 before electrical work.
- 9PPE — Issue AS/NZS 1337.1 safety eyewear, AS/NZS 2161.3 chemical-resistant gloves, AS/NZS 2210.3 safety footwear and P2 respirators for any potential ACM-disturbance task.
- 10PPE — Provide thermal/cryogenic gloves and face shield during refrigerant handling; flame-resistant coveralls (AS/NZS 4824) when working on fuel systems or near ignition sources.
Applicable Codes of Practice
Mandates pre-start inspection, six-monthly competent person inspection and operator training for every vehicle hoist used in the workshop.
Triggers asbestos register, identification and control duties when servicing brake, clutch or gasket components on vehicles manufactured before 31 December 2003.
Requires SDS register, manifest, placarding and exposure controls for oils, coolants, brake fluids, fuels and refrigerants stored or used on site.
Sets the isolation, testing and PPE requirements for battery disconnection and any work on 12V/24V/48V and EV traction systems.
High-Risk Construction Work triggered
Two-post, four-post and scissor vehicle hoists are powered mobile plant; every lift, reposition and lower cycle places workers within the crush zone of energised plant.
PCBU must prepare, consult workers on and retain this SWMS for the life of the work plus two years after any notifiable incident; penalties for failure are substantial and indexed, with the current maximum following the prevailing WHS penalty schedule.
Who this is for
- →Independent mechanical workshop owners and PCBUs
- →Dealership service managers and qualified motor mechanics
- →Mobile roadside and fleet maintenance technicians
- →Heavy vehicle and 4WD specialist repair operators
What you receive
- ✓Editable DOCX template — Microsoft Word compatible
- ✓State-specific WHS legislation schedule (NSW/VIC/QLD/SA/WA/TAS/NT/ACT)
- ✓Hazard register with risk ratings + hierarchy-of-control mapping
- ✓Worker sign-on register, pre-start checklist, and incident escalation flow
Worked example
At a suburban independent workshop, a third-year apprentice is rostered to replace front brake pads and rotors on a 1998 Toyota HiLux booked in for a roadworthy. Before lifting the vehicle, the workshop supervisor opens the Automotive Mechanical Repair SWMS at the morning pre-start brief and walks the apprentice and two other technicians through the hazard register. Because the vehicle pre-dates 2003, the asbestos hazard line item is flagged: the team confirms the control sequence — wet-method brake washer captured in a sealed basin, P2 respirator donned, no compressed-air blow-down, and ACM-suspect waste double-bagged and labelled per the Asbestos Code of Practice. The hoist hazard line drives a documented pre-start hoist check: arm pads inspected, safety locks tested, and the HiLux kerb weight (1,705 kg) verified against the 4,000 kg SWL plate. Each worker signs the SWMS sign-on register. Mid-task, the apprentice notices a seized caliper slide pin requiring penetrating fluid and heat — a deviation from the planned method. Work stops, the supervisor reviews the hot-work and hydrocarbon-fire control on the SWMS, relocates the fuel-line proximity, fits a fire blanket and re-briefs the team. The amendment is initialled on the SWMS, the task resumes safely, and the document is filed for the statutory retention period.
Related legislation
- WHS Act 2011 (model)
- WHS Regulation 2025
- AS 2550 — Cranes, hoists and winches; AS 1418 series