Timber Stair Fabrication (Workshop) SWMS

Timber stair fabrication in a workshop environment involves the prefabrication of stringers, treads, risers and balustrade components using fixed and portable woodworking machinery, jigs, adhesives and mechanical lifting before delivery to site for installation. The work routinely engages high-speed circular and panel saws, spindle moulders, thicknessers, pneumatic nailers, polyurethane and PVA adhesives, and the manual handling of long stringers and assembled flights that frequently exceed 25kg. Because this work forms part of the construction supply chain and falls within the definition of construction work under WHS Regulation 2011 r289, and because it involves the use of powered woodworking machinery, exposure to wood dust (a Schedule 14 hazardous chemical classified as a Group 1 carcinogen by IARC) and repetitive manual handling of awkward loads, a Safe Work Method Statement is mandatory under r299 before work commences. This SWMS documents hazard identification, the hierarchy of controls, consultation arrangements and review triggers required to discharge the PCBU's primary duty under s19 of the WHS Act.

Hazards identified

7 hazards covered, sorted by priority.

Control measures

Hierarchy-of-controls order: elimination → substitution → isolation → engineering → administrative → PPE.

1. 1Elimination — Specify CNC-machined stair components from an offsite supplier where design allows, removing the need for in-house ripping, moulding and sanding of raw stock entirely.
2. 2Elimination — Pre-cut stringers to final length at the supplier yard so long-stock ripping on the workshop table saw is removed from the workflow.
3. 3Substitution — Replace solvent-based polyurethane stair adhesives with low-VOC PVA Type D4 cross-linking adhesive where structural performance per AS 1604 permits.
4. 4Substitution — Substitute MDF risers with pre-finished hardwood ply to eliminate the highest-dust sanding operations associated with MDF edges.
5. 5Engineering — Connect every fixed machine to an M-class LEV system delivering minimum 20 m/s capture velocity at the hood, tested quarterly per AS/NZS 60335.2.69.
6. 6Engineering — Fit table saws with riving knives, crown guards and SawStop-equivalent flesh-detection braking; install power-feeders for all rip cuts over 1.2m.
7. 7Engineering — Use purpose-built stair assembly jigs with hydraulic clamps and roller conveyors to eliminate manual lifting of flights during glue-up and squaring.
8. 8Administrative — Rotate operators off high-noise machinery on a 2-hour cycle, conduct daily pre-start machine checks, and lock out per AS 4024.1603 during blade changes.
9. 9Administrative — Deliver toolbox talks on safe stock-handling, enforce two-person lifts for loads over 25kg per the National Hazardous Manual Tasks CoP, and log SWMS sign-on.
10. 10PPE — Mandate P2 half-face respirators (fit-tested per AS/NZS 1715), Class 5 hearing protection, AS/NZS 1337.1 wrap-around safety glasses, cut-5 gloves for handling and steel-cap boots.

Applicable Codes of Practice

Worked example

At a suburban joinery workshop producing a run of solid blackbutt stairs for a townhouse development, the leading hand opens this SWMS at the 6:45am pre-start huddle around the assembly bench. He walks the three-person crew through the hazard register on page two, pausing on table saw kickback and wood dust because today's job involves ripping 4.2m stringers and sanding 36 treads. The crew confirms the riving knife and crown guard are fitted, the power-feeder is positioned, and the M-class extraction reads 22 m/s at the saw hood on the gauge. Each worker signs the SWMS sign-on register, noting their P2 respirator fit-test expiry date in the column provided. Mid-morning, a stringer binds during a rip cut and the operator stops the saw using the knee-stop. The leading hand pauses production, returns to the SWMS, and applies the documented review trigger: any near-miss requires reassessment before resuming. The crew adds a second roller stand for outfeed support, re-records the control change in the SWMS amendment log, and the three workers re-sign acknowledging the revised control. The document then travels with the completed flights to site so the installation crew inherits the hazard history at delivery handover.

Related legislation

• WHS Act 2011 (model)
• WHS Regulation 2025
• Construction Work CoP; Managing the Risk of Falls at Workplaces CoP

Frequently asked questions