Free PUWER equipment risk assessment

• The MapTrack PUWER equipment risk assessment contains 16 checks across 5 sections. Sections covered: Mechanical Hazards (Reg. 11-12), Control Systems & Stability (Reg. 14-18, 20), Energy & Environmental Hazards (Reg. 13, 19), Health Hazards (Noise, Vibration and COSHH Regulations), Ergonomic & Operational Hazards (Reg. 4-9, 21).
• PUWER has no risk assessment regulation. The duty to assess work equipment risks comes from regulation 3 of the Management Regulations 1999.
• Employers with five or more employees must record the significant findings of the assessment (MHSWR regulation 3).
• Review the assessment when it may no longer be valid or there has been a significant change (regulation 3(3)). No fixed interval is set.
• Check each control against its PUWER duty: regulation 11 for guards, regulations 14 to 16 for start, stop and emergency stop controls.

Learn more about compliance and inspections in MapTrack.

• PUWER Regulation 4 suitability: a documented risk assessment records how the employer judged the work equipment suitable and evaluated the risks before it was put into service.
• Hazard identification: the structured format prompts assessors to consider all relevant hazard categories, including mechanical, electrical, thermal, noise, vibration and ergonomic hazards, reducing the chance of overlooking less obvious risks.
• Risk prioritisation: scoring each hazard by severity and likelihood produces a ranked list that directs resources toward the highest risks first, ensuring control measures are proportionate and effective.
• Control measure traceability: linking each identified hazard to specific PUWER regulation numbers (Regs 5, 9, 11 to 18, 20 to 24) creates a clear audit trail showing which regulatory duty each control measure satisfies.
• Maintenance planning: hazards identified during the risk assessment inform the planned preventive maintenance schedule, inspection intervals and spare parts requirements for each piece of equipment.
• Training alignment: the assessment identifies where operator competence is critical, feeding directly into training plans and competency records for the adequate training PUWER Regulation 9 requires.

• Equipment details: description, make, model, serial or asset number, location, date of purchase or installation, intended use and operating environment.
• Assessment details: assessor name, role, competence statement, date of assessment, reason for assessment (new equipment, modification, relocation, periodic review, post-incident).
• Hazard identification: list every foreseeable hazard category, including entanglement, crushing, shearing, stabbing, puncture, impact, friction or abrasion, high-pressure fluid injection, ejection of parts or material, electrical contact, thermal burn, noise exposure, vibration exposure, dust or fume generation, and ergonomic strain.
• Persons at risk: operators, maintenance personnel, cleaners, passers-by, visitors and contractors who may be exposed to each hazard.
• Existing controls: guards (fixed, interlocked, adjustable), protective devices (light curtains, two-hand controls, pressure mats), emergency stops, warning signs, operating procedures and PPE currently in place.
• Risk scoring: severity rating (e.g. 1 to 5) multiplied by likelihood rating (e.g. 1 to 5) to produce a risk score for each hazard, with defined action bands (low, medium, high, critical).
• Additional control measures: for any hazard where the residual risk is not as low as reasonably practicable (ALARP), specify additional engineering controls, procedural controls, PPE or training required, with responsible person and target completion date.
• Residual risk: re-score each hazard after planned additional controls are implemented to confirm the residual risk is acceptable.
• PUWER regulation mapping: for each control measure, reference the specific PUWER regulation it satisfies (e.g. Reg 11 for guarding dangerous parts, Reg 14 for controls, Reg 20 for stability).
• Review schedule: state when the assessment will be reviewed (e.g. annually, after modification, after incident) and who is responsible for the review.
• Sign-off: assessor signature, responsible manager approval, date.

1. Record the equipment details, operating environment and the reason for the assessment at the top of the form.

   Enter the equipment description, make, model, serial or asset number and location. Describe the intended use, the operating environment (indoor, outdoor, wet, dusty, confined) and any non-standard conditions such as extreme temperatures, corrosive atmospheres or remote locations. State the reason for the assessment: new equipment procurement, modification, change of use, relocation, periodic review or investigation following a near miss or incident.

2. Walk around the equipment and systematically identify every foreseeable hazard, recording who may be harmed and how.

   Inspect the equipment from every access point. Consider each hazard category in turn: mechanical (entanglement, crushing, shearing, impact, ejection), electrical (contact with live parts, static discharge), thermal (hot surfaces, cold surfaces, fire), noise, vibration, ergonomic (manual handling, awkward posture, repetitive motion), and substance hazards (dust, fume, fluid). For each hazard, note which persons are at risk (operators, maintenance staff, cleaners, passers-by) and the mechanism of harm.

3. Evaluate existing control measures against PUWER regulation requirements and score each hazard for severity and likelihood.

   For each hazard, record what controls are already in place (guards, interlocks, emergency stops, procedures, PPE). Check whether each control satisfies the relevant PUWER regulation: Regulation 11 (guarding dangerous parts), Regulation 12 (protection against specific hazards), Regulation 14 (controls), Regulation 15 (stop controls), Regulation 16 (emergency stop), Regulation 20 (stability). Score severity from 1 (minor injury) to 5 (fatality) and likelihood from 1 (very unlikely) to 5 (almost certain). Multiply to produce the risk score.

4. For any hazard where the risk score exceeds the acceptable threshold, specify additional control measures with responsible persons and target dates.

   Apply the hierarchy of controls: elimination, substitution, engineering controls (fixed guards, interlocked guards, light curtains), administrative controls (procedures, training, signage) and PPE. Each additional control measure must reference the PUWER regulation it addresses and have a named responsible person and a target completion date. Where engineering controls are not immediately practicable, document interim measures and the timeline for permanent solutions.

5. Re-score the residual risk after planned controls, confirm it is ALARP, sign the assessment and schedule the next review.

   For each hazard, estimate the residual risk score assuming the additional control measures are fully implemented. If any residual risk remains above the acceptable threshold, add further controls or escalate to senior management for a decision on whether the equipment should be used. Sign the assessment, obtain approval from the responsible manager, and record the next review date. File the completed assessment with the equipment maintenance records.

Practical answers about the form, record keeping and using MapTrack.

This form is a starting point. Check the current requirements that apply to your equipment, work and location. The form alone does not establish compliance.

Each source was read at its publisher and the page checked on 26 October 2026. The publisher's current text is the authority.

• Model Codes of Practice (Safe Work Australia)
• Provision and Use of Work Equipment Regulations 1998 (PUWER)
• Management of Health and Safety at Work Regulations 1999

MapTrack publishes this template. The linked authorities publish their own guidance; they haven't endorsed this form.

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