Smelter & Furnace Demolition SWMS

Demolition of industrial smelters and furnaces is among the most hazardous decommissioning work undertaken in Australia, combining residual thermal energy, crystalline silica and refractory ceramic fibre exposure, heavy-metal contaminated residues (lead, arsenic, cadmium, hexavalent chromium), and structural collapse risk during steel shell cutting. This work is classified High Risk Construction Work under WHS Regulation 2025 section 291 because it involves demolition of load-bearing structures, work in confined or partially enclosed spaces, and disturbance of materials containing hazardous chemicals. A Safe Work Method Statement is mandatory under WHS Regulation 2025 r299 before work commences, must be developed in consultation with workers under r47, and must remain accessible on site for the duration of the works. This SWMS addresses the full demolition sequence from pre-demolition refractory characterisation and residue sampling through controlled cool-down, refractory removal with engineered dust suppression, oxy-fuel and plasma cutting of structural steel, and classification of contaminated waste streams under the relevant state EPA waste tracking framework.

Hazards identified

7 hazards covered, sorted by priority.

Control measures

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

1. 1Elimination — Where furnace integrity permits, specify full mechanical demolition using long-reach excavator with shear attachment from outside the structure, eliminating worker entry into the hot zone entirely.
2. 2Elimination — Mandate complete cool-down verified by thermal imaging below 40°C surface temperature and 60°C internal before any cutting or breaking work commences, eliminating thermal hazard.
3. 3Substitution — Replace dry pneumatic brick breaking with hydraulic splitting or diamond wire sawing using continuous water suppression to substitute high-energy dust generation with low-energy wet methods.
4. 4Substitution — Substitute oxy-fuel cutting with cold cutting methods (hydraulic shears, diamond wire) on contaminated steel sections to eliminate fume generation from heavy-metal coated surfaces.
5. 5Engineering — Install local exhaust ventilation with HEPA H14 filtration at all brick removal points, maintain 0.5 m/s capture velocity verified per AS/NZS 60335.2.69 and pre-shift airflow checks.
6. 6Engineering — Erect independent demolition support frames and progressive bracing engineered by a structural engineer before any load-bearing element is cut, with exclusion zones at 1.5× structure height.
7. 7Engineering — Continuous atmospheric monitoring inside furnace cavity for O2, CO, H2S, SO2 and LEL with alarm-linked forced ventilation per AS/NZS 2865 confined space standard.
8. 8Administrative — Issue daily hot work permits, confined space entry permits, and demolition sequence sign-off by competent supervisor; conduct biological monitoring for lead exposure per WHS r394 schedule.
9. 9Administrative — Pre-demolition hazardous materials survey by occupational hygienist sampling refractory, slag and flue dust for asbestos, RCF, silica and heavy metals; classify waste streams under NEPM.
10. 10PPE — Powered air-purifying respirators with P3/TM3 cartridges, aluminised heat-reflective coveralls for hot zones, Type 5/6 chemical suits for residue handling, FR underlayer, impact gloves and metatarsal boots.

Applicable Codes of Practice

High-Risk Construction Work triggered

Worked example

On a regional copper smelter closure project, the demolition supervisor opens the pre-start brief at 6:15am with the crew of eight assembled at the reverberatory furnace. The SWMS is on the table alongside the daily hot work permit and confined space entry register. Reviewing the hazards section, the supervisor confirms with the leading hand that thermal imaging taken the previous evening showed the southern wall still at 78°C internal — above the 60°C threshold in the SWMS controls. The crew agrees to defer brick removal on that face for 24 hours and redeploy to flue duct dismantling instead, which the SWMS sequence permits. The hygienist reports overnight area monitoring showed lead in dust at 0.04 mg/m³, prompting the supervisor to escalate respiratory protection from half-face P3 to PAPR for the residue handling team, referencing the PPE control line in the SWMS. Each worker signs on against the hazard register, initialling the heavy-metal and silica entries to confirm they have been briefed on health monitoring requirements. At 10:30am, an oxy-fuel cutter notices unexpected discolouration on a steel beam suggesting residual coating; work stops, the SWMS is consulted, and the substitution control directing cold cutting is invoked — a hydraulic shear is brought in, and the change is recorded on the SWMS amendment log before work resumes.

Related legislation

• WHS Act 2011 (model)
• WHS Regulation 2025
• AS 2601 — Demolition of structures

Frequently asked questions