Press brakes are one of the most dangerous machines in a metal fabrication workshop. The closing point between the punch and die creates a severe crush and amputation hazard that has caused numerous serious injuries and fatalities in Australian workplaces. Modern CNC press brakes with light curtains and laser-guarded back gauges have reduced but not eliminated the risk, particularly during setup, tool changes, and manual feeding of small parts. Older hydraulic press brakes without adequate guarding remain in widespread use across small and medium fabrication shops. This template addresses machine guarding, safe operating procedures, and training requirements under the WHS Regulation 2025.
WHS Regulation 2025 Part 4.7 — Plant
Plant with entrapment and crush risk
Managing Risks of Plant in the Workplace (binding 1 July 2026 under Section 26A)
Yes — effective 1 July 2026. Non-compliance is admissible as evidence of breach.
| Hazard | Consequence | Likelihood |
|---|---|---|
| Crush and amputation at the point of operation between punch and die | Finger or hand amputation, crush injuries, death | Possible |
| Struck by sheet metal during bending or springback | Lacerations, fractures, eye injuries | Likely |
| Manual handling injuries from positioning heavy sheet metal | Back injuries, muscle strains, crush injuries to feet | Likely |
| Pinch point hazards during die changes and tool setup | Finger crush, amputation | Possible |
| Noise from press brake operation and material handling | Noise-induced hearing loss | Likely |
| Laceration from sharp sheet metal edges and burrs | Deep cuts, tendon damage | Likely |
Apprentice suffered severe injuries during metal working operations. Training records were absent and supervision was inadequate.
2022 — SafeWork NSW v KML Auto Parts Pty Ltd [2022]
Worker injuries from inadequate safety controls during fabrication operations.
2025 — SafeWork NSW v BI Australia Pty Ltd [2025]
Our WHS consultants build machine-specific SWMS that address guarding, LOTO, and safe operating procedures for your press brake operations.
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