Hazard Risk Register

38 hazards across 18 areas. Residual risk is the rating after current controls — the figure that drives action.

Extreme

High

Moderate

Low

Wash bay

H001
Wet floor — slips and falls
Physical

Existing controls

Squeegee runoff; non-slip footwear PPE

Additional controls

Floor coating to non-slip; warning signs; rubber floor mats at workstations

Inherent risk

12 High

L 4 × C 3

Residual risk

6 Moderate

L 3 × C 2

Owner: Owner Last review: April 2026 Next review: April 2027
H002
High-pressure water injection injury from lance
Physical

Existing controls

Trained operators; never aim at people; lance trigger lock disengaged when not in hand

Additional controls

Annual refresher; tag-out for damaged lances; ≥30 cm distance rule in JSA

Inherent risk

10 High

L 2 × C 5

Residual risk

5 Moderate

L 1 × C 5

Owner: Owner Last review: April 2026 Next review: April 2027

Polishing bay

H003
Hand-arm vibration syndrome (HAVS) from prolonged DA / rotary use
Physical (vibration)

Existing controls

Operator rotation each 60 min; choice of low-vibration tools

Additional controls

Health monitoring (annual symptom check); time-on-tool limits per JSA

Inherent risk

9 Moderate

L 3 × C 3

Residual risk

6 Moderate

L 2 × C 3

Owner: Owner Last review: April 2026 Next review: April 2027
H004
Noise-induced hearing loss from rotary / extractor
Physical (noise)

Existing controls

Hearing protection available; engineering — variable speed

Additional controls

Workplace noise survey; mandatory hearing PPE >85 dB(A); annual hearing test

Inherent risk

9 Moderate

L 3 × C 3

Residual risk

6 Moderate

L 2 × C 3

Owner: Owner Last review: April 2026 Next review: April 2027
H005
Eye injury from compound spatter
Physical

Existing controls

Mandatory eyewear PPE; paint correction taping protocol

Additional controls

Sealed goggles for rotary; eyewash within 10 m

Inherent risk

9 Moderate

L 3 × C 3

Residual risk

4 Moderate

L 2 × C 2

Owner: Lead detailer Last review: April 2026 Next review: April 2027
H006
Spontaneous combustion of polish/oil-soaked microfibre towels
Fire

Existing controls

Sealed metal bin with water until laundered; no warm-pile storage

Additional controls

Train all staff; signage on bin; daily empty

Inherent risk

12 High

L 3 × C 4

Residual risk

4 Moderate

L 1 × C 4

Owner: Owner Last review: April 2026 Next review: April 2027

Coating bench

H007
Isocyanate / silane sensitisation from ceramic coatings
Chemical / health

Existing controls

P2+OV respirator; gloves; ventilation; manufacturer training

Additional controls

Annual respiratory health surveillance; substitute lower-hazard products where possible

Inherent risk

12 High

L 3 × C 4

Residual risk

8 Moderate

L 2 × C 4

Owner: Owner Last review: April 2026 Next review: April 2027

Chemical store / wheel bay

H008
Skin / eye contact with Pacer Mag Wheel Cleaner — strong acid mixture (pH<1, UN 3264 DG 8 PGIII) containing <1% HYDROFLUORIC ACID; H314/H318 severe burns + delayed tissue damage from HF
Chemical (high-hazard)

Existing controls

PVC/Viton gloves + safety goggles + apron (normal use); full-face mask + PVC gumboots (bulk transfer); locked corrosive-resistant storage; SDS on file; eyewash <10 m; calcium gluconate 2.5% gel kept in workshop and each mobile van

Additional controls

Substitute non-HF wheel cleaner for routine work (use Pacer only where alloy oxidation justifies); restrict to trained users; pre-task PPE + antidote check; calcium gluconate gel checked monthly for expiry; HF-specific toolbox talk annually; never decant into food/drink containers; keep separate from metals (Zn/Al) and alkalis

Inherent risk

15 High

L 3 × C 5

Residual risk

5 Moderate

L 1 × C 5

Owner: Owner Last review: April 2026 Next review: April 2027

Chemical store / multi-task

H009
Skin / eye burns and respiratory irritation from Pacer Supa Rip (alkaline pH 12.5, UN 2922 DG 8 PG II, contains sodium hydroxide); used 1:4 to 1:20 across wheel/tyre/engine bay/wheel arch/interior oil-stain — high frequency of exposure
Chemical (corrosive + sensitiser)

Existing controls

Face shield + sealed goggles + chemical-resistant gloves + apron; SDS on file; bunded storage; never decant into food/drink containers; no contact lenses while handling

Additional controls

P2+OV respirator mandatory when using pump/keg sprayers (mist exposure); operator rotation for high-frequency days; track skin reactions (sensitiser); maintain temperature <40 °C in storage; segregate from acids and from aluminium/zinc

Inherent risk

16 High

L 4 × C 4

Residual risk

8 Moderate

L 2 × C 4

Owner: Owner Last review: April 2026 Next review: April 2027

Engine bay

H010
Hydrogen gas evolution from Supa Rip contact with aluminium/zinc components (sodium hydroxide reacts with both)
Chemical / fire

Existing controls

Cover sensitive aluminium/zinc components before applying; rinse thoroughly; ventilate

Additional controls

Documented in JSA 07; pre-/post checklist; never apply to galvanised intake/turbo housings without rinse plan

Inherent risk

9 Moderate

L 3 × C 3

Residual risk

3 Low

L 1 × C 3

Owner: Lead detailer Last review: April 2026 Next review: April 2027
H020
Burns from hot engine components
Physical (thermal)

Existing controls

30-min cool-down rule; touch-test panel before water

Additional controls

Documented in JSA; bay rule enforced

Inherent risk

9 Moderate

L 3 × C 3

Residual risk

6 Moderate

L 2 × C 3

Owner: Lead detailer Last review: April 2026 Next review: April 2027
H021
Compressed air injury
Physical

Existing controls

Regulator ≤30 psi at gun; never on skin

Additional controls

Safety nozzle (ball-type) on all guns

Inherent risk

8 Moderate

L 2 × C 4

Residual risk

4 Moderate

L 1 × C 4

Owner: Owner Last review: April 2026 Next review: April 2027
H022
Vehicle electrical short / start failure after wash
Property / electrical

Existing controls

Cover sensitive components; use water-based degreaser; test-start outside

Additional controls

Pre-/post-checklist; battery disconnect for sensitive vehicles

Inherent risk

9 Moderate

L 3 × C 3

Residual risk

6 Moderate

L 2 × C 3

Owner: Lead detailer Last review: April 2026 Next review: April 2027

Interior detailing

H011
Severe skin burns / eye damage / allergic skin reaction from Malco Leather and Plastic Cleaner (pH 13, Skin corrosion 1A, sensitiser)
Chemical (corrosive + sensitiser)

Existing controls

Sealed goggles + face shield + chemical-resistant gloves + apron; ventilate; eyewash <10 m

Additional controls

Dilute (1:3 to 1:10) before any general use; pre-task PPE check; track skin sensitisation reports; refresher training annually

Inherent risk

12 High

L 3 × C 4

Residual risk

4 Moderate

L 1 × C 4

Owner: Owner Last review: April 2026 Next review: April 2027
H017
Bloodborne pathogen / sharps in vehicle interior
Biological

Existing controls

Pre-clean visual sweep; tongs; nitrile + long sleeves

Additional controls

Hep B vaccination offered; sharps container in van; refusal protocol if hazard exceeds capability

Inherent risk

12 High

L 3 × C 4

Residual risk

8 Moderate

L 2 × C 4

Owner: Owner Last review: April 2026 Next review: April 2027
H018
Burn from steam wand / extractor hot water
Physical (thermal)

Existing controls

Heat-resistant gloves; trained operators

Additional controls

Lock-out when changing wand; signage to nearby workers

Inherent risk

9 Moderate

L 3 × C 3

Residual risk

6 Moderate

L 2 × C 3

Owner: Lead detailer Last review: April 2026 Next review: April 2027
H019
Ozone exposure during odour treatment
Chemical / health

Existing controls

Vehicle empty + locked during cycle; door warning sign; 2 hr ventilation after; operator never inside during treatment (per JSA 12)

Additional controls

JSA 12 Ozone Treatment + Poster_OD_DoNotEnter_Ozone door sign + SOP-OD-001 Odour Removal parent procedure

Inherent risk

8 Moderate

L 2 × C 4

Residual risk

4 Moderate

L 1 × C 4

Owner: Owner Last review: April 2026 Next review: April 2027

Interior detailing — mould remediation

H012
Mould spore exposure during disturbance (allergen / sensitiser / mycotoxin) + hydrogen peroxide oxidiser exposure from Actichem Percide
Biological + chemical

Existing controls

Pre-task assessment; P2 fit-tested respirator; sealed goggles; nitrile gloves (double); apron; cabin ventilation; Percide oxidiser segregated from combustibles; equipment decon between vehicles

Additional controls

Refusal protocol if contamination exceeds capability; fit-testing record for P2 respirator; track post-job respiratory / skin / eye symptoms; consider escalating heavy contamination to specialist remediator

Inherent risk

12 High

L 3 × C 4

Residual risk

4 Moderate

L 1 × C 4

Owner: Owner Last review: April 2026 Next review: April 2027

Exterior wash — solvent prep

H013
Pacer Prepare It (preparation solvent) — hydrocarbon vapour inhalation, skin defatting, fire ignition risk, aspiration hazard if swallowed
Chemical (flammable solvent)

Existing controls

Apply to microfibre only (never panel); P2+OV respirator; gloves + eyewear; bay door open; no ignition sources within 3 m; flame-resistant cabinet storage

Additional controls

Quantity limits enforced; SDS confirmation pending — re-rate when classification confirmed; toolbox talk on hot-work exclusion

Inherent risk

12 High

L 3 × C 4

Residual risk

8 Moderate

L 2 × C 4

Owner: Owner Last review: April 2026 Next review: April 2027

Chemical store

H014
Skin / eye contact with other corrosives (iron remover, alkaline wheel cleaner)
Chemical

Existing controls

PPE; SDS on file; bunded shelving

Additional controls

Eyewash <10 m; substitute pH-neutral cleaner where suitable

Inherent risk

9 Moderate

L 3 × C 3

Residual risk

6 Moderate

L 2 × C 3

Owner: Owner Last review: April 2026 Next review: April 2027
H015
Solvent fire (IPA, tar remover, prep sprays)
Fire

Existing controls

Flame-resistant cabinet; no ignition sources; CO2 extinguisher

Additional controls

Quantity limits enforced; quarterly stock-take; ventilation interlock if upgraded

Inherent risk

10 High

L 2 × C 5

Residual risk

5 Moderate

L 1 × C 5

Owner: Owner Last review: April 2026 Next review: April 2027
H016
Aerosol can rupture from heat / sun
Chemical / fire

Existing controls

Stored cool / out of sun; max 50 cans on site

Additional controls

Temperature-monitored storage in summer; signage

Inherent risk

8 Moderate

L 2 × C 4

Residual risk

4 Moderate

L 1 × C 4

Owner: Owner Last review: April 2026 Next review: April 2027

Headlight / wet sand

H023
Polycarbonate dust inhalation
Chemical / health

Existing controls

Wet sanding only; P2 respirator; ventilation

Additional controls

Local exhaust at sanding station

Inherent risk

9 Moderate

L 3 × C 3

Residual risk

6 Moderate

L 2 × C 3

Owner: Owner Last review: April 2026 Next review: April 2027
H024
Urethane sealant skin sensitisation
Chemical / health

Existing controls

Gloves; SDS reviewed

Additional controls

Substitute acrylic sealant where suitable; track skin reaction reports

Inherent risk

9 Moderate

L 3 × C 3

Residual risk

6 Moderate

L 2 × C 3

Owner: Owner Last review: April 2026 Next review: April 2027

Mobile / on-site

H025
Traffic / pedestrians at customer site
Physical

Existing controls

Hi-vis; cones; van parked as barrier

Additional controls

Site survey checklist completed; refusal protocol if unsafe

Inherent risk

12 High

L 3 × C 4

Residual risk

8 Moderate

L 2 × C 4

Owner: Detailer on-site Last review: April 2026 Next review: April 2027
H026
Lone-worker injury / medical event
Health / safety

Existing controls

Mobile phone on person; check-in every 2h; first aid kit in van

Additional controls

GPS lone-worker app; defined escalation procedure

Inherent risk

12 High

L 3 × C 4

Residual risk

8 Moderate

L 2 × C 4

Owner: Owner Last review: April 2026 Next review: April 2027
H027
Outdoor electrical use without RCD
Electrical

Existing controls

Portable RCD on every circuit; visual lead check

Additional controls

Tagged & tested per AS/NZS 3760; mandatory pre-start check

Inherent risk

15 High

L 3 × C 5

Residual risk

5 Moderate

L 1 × C 5

Owner: Owner Last review: April 2026 Next review: April 2027
H028
UV exposure / heat stress (NZ summer)
Health

Existing controls

Long-sleeve clothing; SPF50+; hydration

Additional controls

Re-schedule extreme heat; shade structure for long jobs

Inherent risk

12 High

L 4 × C 3

Residual risk

6 Moderate

L 2 × C 3

Owner: Owner Last review: April 2026 Next review: April 2027
H029
Wash water / chemical entering stormwater
Environment

Existing controls

Use grass / soak pad; council awareness

Additional controls

Portable water-collection mat; trade-waste plan documented

Inherent risk

9 Moderate

L 3 × C 3

Residual risk

6 Moderate

L 2 × C 3

Owner: Owner Last review: April 2026 Next review: April 2027

Marine / RV / Comm.

H030
Fall from height (>3 m) on tall vehicle / boat
Physical

Existing controls

Two-person; ladder selection; fall-arrest harness for >3 m unprotected

Additional controls

MEWP / scaffold preference over ladder; suspension trauma rescue plan

Inherent risk

15 High

L 3 × C 5

Residual risk

5 Moderate

L 1 × C 5

Owner: Owner Last review: April 2026 Next review: April 2027
H031
Confined space hazard (RV cabin, boat hold)
Physical / health

Existing controls

All hatches open; portable fan; buddy system

Additional controls

Confined space awareness training; gas monitor for engine bay use

Inherent risk

12 High

L 3 × C 4

Residual risk

4 Moderate

L 1 × C 4

Owner: Owner Last review: April 2026 Next review: April 2027
H032
Overhead power line strike
Electrical

Existing controls

≥4 m exclusion; site survey

Additional controls

Permit-to-work for any work within 4 m; lines company contact

Inherent risk

10 High

L 2 × C 5

Residual risk

5 Moderate

L 1 × C 5

Owner: Owner Last review: April 2026 Next review: April 2027

Workshop general

H033
Manual handling — buckets, equipment, customer wheels/seats
Ergonomic

Existing controls

Two-person lift policy; trolleys available

Additional controls

Manual handling training; bucket dollies; height-adjustable benches

Inherent risk

12 High

L 4 × C 3

Residual risk

6 Moderate

L 2 × C 3

Owner: Owner Last review: April 2026 Next review: April 2027
H034
Workplace stress / fatigue (rush, long jobs)
Psychosocial

Existing controls

Reasonable scheduling; breaks

Additional controls

Fatigue & Working Hours Policy (50 hr/wk cap, 4 hr polisher cap, self-declaration); HAVS reporting; EAP referral pathway

Inherent risk

9 Moderate

L 3 × C 3

Residual risk

6 Moderate

L 2 × C 3

Owner: Owner Last review: April 2026 Next review: April 2027

External generator area / refuelling

H035
Petrol vapour ignition during storage or refuelling — flash point ~-43 °C, vapour ignites at ambient temp
Chemical / fire

Existing controls

Stored externally at generator area, never inside workshop; approved jerry can with flame arrester; chained, weatherproof; 20 L max

Additional controls

JSA 10 Generator Refuelling procedure; External Petrol Storage A4 sign at jerry location; toolbox talk Week 4; refuelling only when generator OFF and COOL; ignition sources >3 m; refilling jerry at petrol station only (never decant on site)

Inherent risk

15 High

L 3 × C 5

Residual risk

5 Moderate

L 1 × C 5

Owner: Owner Last review: April 2026 Next review: April 2027

Interior detailing — odour treatment

H036
Chlorine dioxide (ClO₂) gas exposure during odour bomb treatment — toxic by inhalation, WES TWA 0.1 ppm
Chemical / health

Existing controls

Vehicle locked + door warning sign affixed before treatment commences; operator never inside during treatment; treatment outdoors / open-bay only

Additional controls

JSA 11 ClO₂ Odour Bomb procedure (covers Method A aerator + Method B static); Poster_OD_DoNotEnter_ClO2 door sign; SOP-OD-001 parent procedure; respirator fit-testing required (annual, AS/NZS 1715); half-face respirator with gas/P2 cartridges for any handling or post-treatment re-entry; 2 hr ventilation before re-entry; toolbox talk Week 7

Inherent risk

10 High

L 2 × C 5

Residual risk

5 Moderate

L 1 × C 5

Owner: Owner Last review: April 2026 Next review: April 2027

Workshop premises (general)

H037
Visitor, customer, or contractor exposure to workshop hazards (chemicals, vehicle movement, slips, electrical) — HSWA s36 PCBU duty extends to non-workers
Multi-source / health & safety

Existing controls

Visitors stay with TDS host; no unsupervised access to workshop floor; closed-toe footwear required; chemical store access controlled

Additional controls

Visitor / Sign-In Register (xlsx) with Visitor Induction tab (60-second brief) + Contractor Induction tab; Contractor Management Procedure for any paid work on site; pre-engagement check (insurance, licensing, JSA review); hot work permit for welding/grinding within 5 m of chemical store or petrol jerry; sign-out on departure (also serves as evacuation roll-call)

Inherent risk

12 High

L 3 × C 4

Residual risk

8 Moderate

L 2 × C 4

Owner: Owner Last review: April 2026 Next review: April 2027

All work locations + comms channels

H038
Bullying, harassment, discrimination — psychosocial harm to workers (and from customers off-site); breach of HSWA + Human Rights Act + Employment Relations Act
Psychosocial

Existing controls

Open-door culture; small team (owner + 1); behavioural standards expected via induction

Additional controls

Bullying & Harassment Policy (defines behaviours, reporting pathways: owner OR backup officer James Swan when owner is the subject; external pathways: WorkSafe / HRC / Employment NZ / Police); 20-working-day investigation timeframe; customer harassment of worker → customer asked to leave / job declined, owner backs worker; toolbox talk Week 11; manager investigation training (within 12 months of role)

Inherent risk

8 Moderate

L 2 × C 4

Residual risk

4 Moderate

L 1 × C 4

Owner: Owner Last review: April 2026 Next review: April 2027

Source: 02_Hazard_Risk_Register/Hazard_Risk_Register.xlsx in the H&S system. Edit in Excel, then run npm run sync-data.